Golf ball incorporating transition color region and method of making same

ABSTRACT

A golf ball comprising a subassembly such as a cover and a coating layer disposed entirely about an outer surface of the subassembly; wherein the coating layer has a first color region, a second color region, and a transition color region that is transitionally disposed between the first color region and the second color region. The first color region has a first color appearance; the second color region has a second color appearance that is different than the first color appearance; and the transition color region has a transitional color appearance that is comprised of the first color appearance and the second color appearance. The transitional color region may be disposed circumferentially about the outer surface of the cover.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.63/125,040, filed Dec. 14, 2020, which is hereby incorporated herein inits entirety.

FIELD OF THE INVENTION

The field of the invention broadly comprises golf balls having anoverall transitional color appearance; and the methods for making same.

BACKGROUND OF THE INVENTION

Both professional and amateur golfers use multi-piece, solid golf ballstoday. Basically, a two-piece solid golf ball includes a solid coreprotected by a cover. The core is made of a natural or synthetic rubbersuch as polybutadiene, styrene butadiene, or polyisoprene. The cover maybe made of a variety of materials including ethylene acid copolymerionomers, polyamides, polyesters, polyurethanes, and/or polyureas.

Three-piece, four-piece, and even five-piece balls have become morepopular over the years. Golfers are playing with multi-piece balls forseveral reasons, including availability of lower-cost materials and thedevelopment of new manufacturing technologies which make it possible andcost-effective to produce a multi-layered golf ball having uniquedesirable resulting performance characteristics. In multi-layered golfballs, each of the core, intermediate layer and cover can be single ormulti-layered, and properties such as hardness, modulus, compression,resilience, core diameter, intermediate layer thickness and coverthickness can be preselected and coordinated to target playcharacteristics such as spin, initial velocity and feel of the resultinggolf ball.

While conventional golf balls are white, some golfers enjoydistinguishing themselves on the course by playing a golf ball having aunique visual appearance. Accordingly, golf ball manufacturers haveapplied localized distinctive colored indicia/markings such astrademarks, symbols, logos, designs, letters, identification numbers,model names and/or on the golf ball's surface using, for example, inkedprefab printing plates/stamps and/or pad-printing, ink-jet printing,dye-sublimation, or other suitable printing methods.

Meanwhile, coloring agents/colorants such as pigments, dyes, tints, inksand the like have also been incorporated in golf balls in several ways.In some applications, the coloring agents/colorants have beenmixed/blended directly into a golf ball layer master batch beforesetting or curing which then becomes an inner core, intermediate layerand/or outermost cover layer after final cure. Additionally, coloredcoating layers have been applied about the outer surface of golf balllayers via numerous methods such as spraying, dipping, rolling, wiping,brushing, thermoforming, masking, transferring, and/or surfacepenetration by a colorant into a golf ball layer/coating.

In fact, to date, golf ball manufacturers have produced a number of golfballs having unique, patentably distinct overall golf ball colorappearances. Nevertheless, there remains a need for a golf ball whereinthe overall golf ball color appearance transitions from a first colorappearance within a first color region into a second color appearancewithin a second color region (and vice versa) via a transition colorregion that is transitionally disposed between the first color regionand the second color region without any visually apparentboundary/border between color regions.

The present golf balls of the invention and methods of making sameaddress and solve this need without negatively impacting important golfball properties and characteristics and meanwhile can be implementedcost effectively within existing golf ball manufacturing processes.

SUMMARY OF THE INVENTION

Accordingly, golf balls of the invention have an overall golf ball colorappearance that is comprised of two differing color regions whichtransition into and from each other within a transition color regionthat is transitionally disposed therebetween without any visuallyapparent boundary/border between color regions.

In one embodiment, a golf ball of the invention comprises a core, acover and a coating layer disposed entirely about an outer surface ofthe cover. The coating layer has a first color region having a firstcolor appearance; a second color region having a second color appearancethat is different than the first color appearance; and a transitioncolor region that is transitionally disposed between the first colorregion and the second color region and has a transitional colorappearance comprised of the first color appearance and the second colorappearance.

As used herein, the term “transitionally disposed” means that thetransition color region transitions from and into each of the firstcolor region and the second color region without being defined by anyvisually apparent boundary/border there between. And yet, the colorappearances within each color region can be measured using a coloranalysis device such as a spectrophotometer, whereby color appearance isrepresented in terms of tristimulus colorimetry as discussed more fullyfurther below.

The transition color region may be disposed circumferentially about theouter surface of the cover.

In a particular embodiment, the first color appearance is at leastpartially overlaid with the second color appearance within thetransition color region and the second color appearance is at leastpartially overlaid with the first color appearance within the transitioncolor region.

In one specific embodiment, the cover comprises a plurality of dimples,and the coating layer is applied onto the outer surface of the coversuch that more dimples of the plurality are located within thetransition color region of the coating layer than are located withineach of the first color region and the second color region of thecoating layer.

In another specific embodiment, the cover comprises a plurality ofdimples, and the coating layer is applied onto the outer surface of thecover such that more dimples of the plurality are located within each ofthe first color region and the second color region of the coating layerthan are located within the transition color region of the coatinglayer.

In yet another specific embodiment, the cover comprises a plurality ofdimples, and the coating layer is applied onto the outer surface of thecover such that an equal number of dimples of the plurality are locatedwithin each of the first color region, the second color region, and thetransition color region of the coating layer.

Alternatively, the coating layer may be applied onto the cover such thatat least one dimple is partially located in the transition color regionof the coating layer and partially located in one of the first colorregion or the second color region.

In another embodiment, the cover comprises a plurality of dimples, andthe coating layer is applied onto the cover such that greater than onerow of dimples and up to seven rows of dimples are located within thetransition color region of the coating layer. In another particularembodiment, the cover comprises a plurality of dimples, and the coatinglayer is applied onto the cover such that at least four rows of dimplesare located within each of the first color region and the second colorregion of the coating layer.

In one embodiment, the cover has at least one transition dimple that islocated within the transition color region and has a transition dimplesurface that is coated with the first color appearance and the secondcolor appearance such that the first color appearance and the secondcolor appearance are juxtaposed on the transition dimple surface. In aspecific such embodiment, the transition dimple has a first side and asecond side; wherein a first pole of the first color region is closer tothe first side than the second side; and wherein a second pole of thesecond color region is closer to the second side than the first side;and wherein the first color appearance is located on the second side andthe second color appearance is located on the first side.

In another embodiment, a first pole of the golf ball is included in thefirst color region; an opposing pole of the golf ball is included in thesecond color region; and an equator of the golf ball is disposed betweenthe first pole and the second pole and is at least partially located inthe transition color region.

In this regard, the “equator” is the line that extends circumferentiallyabout the outer surface of the golf ball and is equi-distant between thefirst pole and the second pole, and does not necessarily align with theparting line of the golf ball.

In a specific embodiment, the cover has a third color appearance that isopaque, translucent, clear-colored, or combinations thereof; and thefirst color appearance and/or the second color appearance isclear-colored, translucent, or at least partially transparent; such thatthe transitional color appearance is comprised of each of the firstcolor appearance, the second color appearance, and at least a portion ofthe third color appearance.

In another specific embodiment, the transition color region istransitionally disposed about an equator of the golf ballasymmetrically; and the cover has a third color appearance that isopaque, translucent, clear-colored, or combinations thereof; and eitherthe first color appearance or the second color appearance isclear-colorless; such that the transitional color appearance iscomprised of the first color appearance or the second color appearanceand at least a portion of the third color appearance.

Moreover, the cover may have a third color appearance that is opaque,translucent, clear-colored, or combinations thereof.

The invention also relates to a method of making a golf ball of theinvention, comprising the steps of: providing a subassembly; providing acoating layer about the subassembly by: applying a first colorant havinga first color appearance onto an outer surface of the subassembly at afirst pole of the subassembly; applying a second colorant having asecond color appearance that is different than the first colorappearance onto the outer surface of the subassembly at an opposing polethereof; such that: the first colorant creates a first color region ofthe coating layer on the outer surface of the subassembly that includesthe first pole and has the first color appearance; and the secondcolorant creates a second color region of the coating layer on the outersurface of the subassembly that includes the opposing pole and has thesecond color appearance; and the first colorant and the second colorantcollectively create a transition color region that is transitionallydisposed between the first color region and the second color region andhas a transitional color appearance that is comprised of the first colorappearance and the second color appearance. The transition color regionmay extend circumferentially about the outer surface of the subassembly.

In one embodiment, a first colorant spray gun applies the first colorantonto the outer surface of the subassembly at the first pole and a secondcolorant spray gun applies the second colorant onto the outer surface ofthe subassembly at the opposing pole; and the transitional colorappearance is created and/or adjusted within the transition color regionby pre-selecting and/or coordinating at least one of i) relative volumesof first colorant and second colorant use; ii) an atomization pressureof each of the first colorant spray gun and the second colorant spraygun; ii) a spray gun pressure of each of the first colorant spray gunand the second colorant spray gun; and/or order that each of the firstcolorant spray gun and the second colorant spray gun spray colorant ontothe outer surface of the subassembly.

In one particular embodiment, the first colorant and the second colorantare applied onto the outer surface of the subassembly at opposing polesof the subassembly simultaneously.

In another particular embodiment, the first colorant and the secondcolorant are applied onto the outer surface of the subassembly atopposing poles of the subassembly sequentially.

In one embodiment, the first colorant and the second colorant coat theouter surface of the subassembly within the transition color region suchthat at least one portion of the coating layer is comprised of the firstcolorant being overlaid with the second colorant and such that at leastone different portion of the coating layer is comprised of the secondcolorant being overlaid with the first colorant.

In another embodiment, a surface coverage ratio of percent surfacecoverage of the first colorant within the first color region to percentsurface coverage of the second colorant within the second color regionis about 1:1; and surface coverage of the first colorant is greater thansurface coverage of the second colorant adjacent the first color region;and surface coverage of the second colorant is greater than surfacecoverage of the first colorant adjacent the second color region.

In a specific such embodiment, the first colorant is overlaid with thesecond colorant within the transition color region adjacent the firstcolor region; and the second colorant is overlaid with the firstcolorant within the color region adjacent the second color region.

As used herein, the term “surface coverage” refers to thevolume/concentration/amount of colorant coating the subassembly at agiven location on the surface of the subassembly (such as a coversurface).

In yet another embodiment, the first colorant and the second colorantcoat a transition dimple surface of at least one transition dimple ofthe subassembly within the transition color region such that the firstcolor appearance and the second color appearance are juxtaposed on thetransition dimple surface.

Once again, the cover may have a third color appearance that is opaque,translucent, clear-colored, or combinations thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects of the present invention as set forth in theappended claims may be more fully understood with reference to, but notlimited by, the following detailed description in connection with thefollowing accompanying drawings in which like numerals refer to likeelements of the inventive golf ball:

FIG. 1 is a perspective view of a golf ball of the invention accordingto one embodiment;

FIG. 2 is a perspective view of a golf ball of the invention accordingto another embodiment;

FIG. 3 is a perspective view of a golf ball of the invention accordingto yet another embodiment;

FIG. 4 is a perspective view of a golf ball of the invention accordingto a specific embodiment;

FIG. 5 is a partial view of the golf ball of the invention depicted inFIG. 4; and

FIG. 6 is a partial view of the golf ball of the invention depicted inFIG. 1.

DETAILED DESCRIPTION

Advantageously, golf balls of the invention have an overall golf ballcolor appearance that is comprised of two differing color regions whichtransition into and from each other within a transition color regiontherebetween without any visually apparent boundary/border between colorregions.

In one embodiment, a golf ball of the invention comprises a core, acover and a coating layer disposed entirely about an outer surface ofthe cover; wherein the coating layer has a first color region having afirst color appearance; a second color region having a second colorappearance that is different than the first color appearance; and atransition color region that comprises the first color appearance andthe second color appearance and is transitionally disposed between thefirst color region and the second color region.

The transition color region transitions from and into each of the firstcolor region and the second color region and is not defined by avisually apparent boundary/border there between. Yet, desirably, in golfballs of the invention, the boundary/border between color regions may bedetected and assessed/ascertained via color analysis using, for example,a spectrophotometer (discussed and detailed more fully herein furtherbelow such as in connection with example golf balls EX. 1-EX. 6 of TABLEI) and represented in terms of tristimulus colorimetry.

Thus, the first color region has a first color appearance that isspectrophotometer-measurable and the second color region has a secondcolor appearance that is spectrophotometer-measurable. In turn, thetransition color region therebetween has a transitional color appearancethat is comprised of a plurality of blends of the first color appearanceand the second color appearance—each likewise beingspectrophotometer-measurable.

It is also possible for portions of the transitional color appearancewithin the transition color region to comprise instances of solely thefirst color appearance or solely the second color appearance, with thelimitations being that the transitional color appearance never comprisessolely the first color appearance adjacent the first color region, andnever comprises solely the second color appearance adjacent the secondcolor region.

Moreover, the cover may have a third color appearance that is opaque,translucent, clear-colored, or combinations thereof. As with the firstcolor appearance and the second color appearance, the third colorappearance of the cover is measurable via color analysis using, forexample, a spectrophotometer and represented in terms of tristimuluscolorimetry, and may even include white and black and any known coloreffects.

Furthermore, the coating layer may be applied onto the cover such thatat least one dimple is partially located in the transition color regionof the coating layer and partially located in one of the first colorregion or second color region. For example, a first portion of thedimple may be coated with a spectrophotometer-measured first colorappearance and be located in the first color region while an adjacenttransition portion of the dimple is coated with aspectrophotometer-measured transitional color appearance (e.g., a blendof the first color appearance and the second color appearance or solelythe second color appearance.

Conversely, a first portion of the dimple may be coated with aspectrophotometer-measured second color appearance and be located in thesecond color region while an adjacent transition portion of the dimpleis coated with a spectrophotometer-measured transitional colorappearance (e.g., a blend of the first color appearance and the secondcolor appearance or solely the first color appearance.

In one embodiment, the transitional color appearance can be developedsuch that the degree of coverage of the first color appearance on theouter surface of the subassembly/cover reduces progressing from adjacentthe first color region toward the second color region. The blends willtherefore be comprised more primarily of the first color appearance thanof the second color appearance closer to the first color region.

In turn, the degree of coverage of the second color appearance on theouter surface of the subassembly/cover can be reduced progressing fromadjacent the second color region toward the first color region. Theblends will therefore be comprised more primarily of the second colorappearance than of the first color appearance closer to the second colorregion.

By “degree of coverage”, it is meant the surface area over which a givenamount of paint or other colorant will spread and hide the surface(e.g., cover) that it is coating.

Therefore, in one particular embodiment, a blue colorant may be sprayedonto or otherwise applied at a first pole of the cover (or othersubassembly) and a pink colorant may be sprayed onto or otherwiseapplied at an opposing pole of the cover (or other subassembly) suchthat the first color region has the color appearance of the bluecolorant, the second color region has the color appearance of pinkcolorant, and the transitional color region has a transitional colorappearance that is comprised of a plurality of blends of the bluecolorant and the pink colorant. The transitional color appearance of thetransitional color region may be comprised of blends of the bluecolorant and the pink colorant which transition from being morepredominantly blue, closer to the first color region, to being morepredominantly pink, closer to the second color region.

The first color appearance and second color appearance may differ bycolor (hue) or have the same hue but differ in some other color measureregard such as by Chroma, lightness, etc. The coating layerapplied/provided onto a subassembly may be transparent and/ortranslucent and/or opaque. Meanwhile, the coating layer applied/providedonto the subassembly may be either glossy, metallic or have a mattefinish.

And any known color effects may be added to or included in the coatingmaterials applied/provided onto a golf ball of the invention as desiredto create a golf ball of the invention. Additionally, the coating layerapplied/provided on the subassembly may be solvent-borne, water-borneand/or powdered.

The subassembly/substrate being coated, such as a covered or coated golfball, can itself have a single color or be multi-colored such as havingtwo differently colored hemispheres. The substrate being coated canitself be at least opaque, clear-colored, translucent (so as to be atleast partially transparent) and may in some embodiments furthercontribute to and participate in the overall golf ball transitionalcolor appearance, especially if the coating layer is clear-colored,translucent or otherwise at least partially transparent.

For example, in one specific embodiment, the cover may have a thirdcolor appearance that is opaque, translucent, clear-colored, orcombinations thereof; while the first color appearance and/or the secondcolor appearance is clear-colored, translucent or at least partiallytransparent; such that the transitional color appearance is comprised ofeach of the first color appearance, the second color appearance, and atleast a portion of the third color appearance. In this embodiment, atleast a portion of the third color appearance of the cover (or othersubassembly) and each of the first color appearance and the second colorappearance collectively participate in creating the transitional colorappearance within the transition color region without any visuallyapparent boundary/border between color regions. In one such embodiment,the transition color region is transitionally disposed about an equatorof the golf ball symmetrically.

In a different embodiment, the transition color region is transitionallydisposed about an equator of the golf ball asymmetrically. In one suchembodiment, the cover has a third color appearance that is opaque,translucent, clear-colored, or combinations thereof; and one of thefirst color appearance or the second color appearance isclear-colorless; such that the transitional color appearance iscomprised of at least a portion of third color appearance and of eitherthe first color appearance or the second color appearance. In thisembodiment, at least a portion of the third color appearance of thecover/subassembly and either the first color appearance or the secondcolor appearance (whichever is not clear-colorless) collectivelyparticipate in creating the transitional color appearance within thetransition color region without any visually apparent boundary/borderbetween color regions.

This transitional color appearance can be developed such that thecolorant of whichever of the first color appearance or the second colorappearance is not clear-colorless has a degree of coverage on the outersurface of the subassembly/cover that reduces progressing from the poleat which the non-clear-colorless colorant is applied onto the outersurface toward the opposing color region. Meanwhile, the degree ofcoverage of clear-colorless “colorant” also reduces on the surface ofthe subassembly progressing from the pole of the golf ball where theclear-colorless colorant is sprayed onto the outer surface of thesubassembly toward the opposing color region. Thus, within thetransitional color region, there will be instances wherein theclear-colorless colorant (first color appearance or second colorappearance) is overlaid with the non-clear colorless colorant; and viceversa, wherein the non-clear colorless colorant is overlaid with theclear-colorless colorant.

While the embodiments above describe the coating layer being formedabout a cover, it is to be understood that the coating layer having atransitional color appearance may be formed or otherwise applied aboutany golf ball subassembly. For example, it is envisioned that a coloredcoating may be disposed between the cover and the coating layer andcontribute to and participate in creating the transitional colorappearance of the golf ball's transition color region. The coloredcoating may be opaque, translucent or clear-colored, and therefore insome instances a color appearance of the underlying cover itself cancontribute to the transitional color appearance through such a coating.

A golf ball of the invention may be even more fully understood withreference to, but not limited by, the three inventive golf ballsdepicted in FIG. 1, FIG. 2 and FIG. 3 as follows. In each of golf ball 2of FIG. 1, golf ball 4 of FIG. 2, and golf ball 6 of FIG. 3, coatinglayer 8 comprises first color region 10, second color region 12, andtransitional color region 14 that is transitionally disposed betweenfirst color region 10 and second color region 12. First color region 10has a first color appearance 16, and second color region 12 has a secondcolor appearance 18 that is different than first color appearance 16.

Meanwhile, transitional color region 14 has a transitional colorappearance which includes but is not limited to: i) 20 a which isproduced from first color appearance 16 partially overlapping secondcolor appearance 18 within transitional color region 14; and/or ii) 20 bwhich is produced from second color appearance 18 partially overlappingfirst color appearance 16 within transitional color region 14; and/oriii) 20 c (see golf balls 2 and 4 of FIG. 1 and FIG. 2, respectively)wherein first color appearance 16 is located on a dimple 19 of the golfball closer to pole 38 than is second color appearance 18 on that samedimple 19.

Of course, it is also envisioned that alternatively, embodiment, 20 cmay be produced where second color appearance 18 is located on dimple 19of the golf ball closer to pole 36 than is first color appearance 16 onthat same dimple 19. Meanwhile, FIG. 6 is an enlarged partial view ofgolf ball 2 of FIG. 1 that highlights the numerous possible differingcolor appearances forming a transitional color appearance withintransition color region 14 such as but not limited to 20 a, 20 b, and/or20 c.

In a specific embodiment, at least one transition dimple of the cover islocated within the transition color region and has a transition dimplesurface that is coated with the first color appearance and the secondcolor appearance such that the first color appearance and the secondcolor appearance are juxtaposed on an outer surface of the transitiondimple.

In a particular such embodiment, the transition dimple has a first sideand a second side; wherein a first pole of the first color region iscloser to the first side than the second side; and wherein a second poleof the second color region is closer to the second side than the firstside; and wherein the first color appearance is located on the secondside and the second color appearance is located on the first side.

The invention may also be more fully understood with reference to, butnot limited by, inventive golf ball 24 depicted in FIG. 4 whichevidences numerous possible transitional color appearances which may becreated within transition color region 14 of coating layer 25 of golfball 24.

In FIG. 4, coating layer 25 of golf ball 24 has a first color region 10having a first color appearance 16 therein denoted by “•” and a secondcolor region 12 having a second color appearance 18 therein denoted by“+”. It is envisioned that “•” and “+” can each be produced on golf ball24 using any known differing coloring agents/compositions.

Meanwhile, coating layer 25 of golf ball 24 of FIG. 4 has a transitioncolor region 14 that includes numerous different ways that first colorappearance “•” and second color appearance “+” can be appear togethertransitionally within transition color region 14 and between first colorregion 10 and second color region 12.

In turn, FIG. 5 is a partial view 28 of golf ball 24 of FIG. 4. Thelocation of partial view 28 on golf ball 24 of FIG. 4 is indicated onFIG. 4 by bracketing so that FIG. 4 and FIG. 5 may be consideredtogether. Partial view 28 of FIG. 5 highlights a specific embodimentwherein transition color region 14 of coating layer 25 of golf ball 24of FIG. 4 has a particular dimple transitional color appearance 20 d.

Specifically, at least one transition dimple 29 of golf ball 24 islocated within transition color region 14 and has a transition dimplesurface 30 that is coated with first color appearance 16 “•” and secondcolor appearance 18 “+” such that first color appearance 16 “•” andsecond color appearance 18 “+” are juxtaposed on transition dimplesurface 30 of transition dimple 29. Moreover, transition dimple 29 has afirst side 32 and a second side 34; wherein a first pole 36 of firstcolor region 10 is closer to first side 32 than the second side 34; andwherein a second (opposing) pole 38 of second color region 12 is closerto second side 34 than to first side 32; and wherein first colorappearance 16 “•”, on transition dimple surface 30, is located on secondside 34, while second color appearance 18 “+”, on transition dimplesurface 30, is located on the first side 32.

In golf balls of the invention, a color assessment within each of firstcolor region 10, second color region 12 and transition color region 14may be made, for example, in terms of tristimulus colorimetry. In thisregard, the following CIELAB coordinates may be measured: lightness(L*), chroma (C*), hue angle from 0° to 360° (h°), (a*) value(represents the degree of redness (positive a*) and greenness (negativea*) and (b*) value (represents the degree of yellowness (positive b*)and blueness (negative b*).

Such measurements may be taken in each of the first color region, secondcolor region and transition color region of a golf ball of the inventionusing, for example, a Gretag Macbeth CE 7000A spectrophotometer underilluminant D65, with a 10° standard observer.

Accordingly, in a specific embodiment, the first color region may have afirst color appearance with first pre-selected CIELAB coordinates L₁*,a₁*, b₁*, C₁*, h₁° resulting from a first colorant being applied ontothe outer surface of a subassembly (such as a cover) at a first polethereof. In turn, the second color region may have a second colorappearance with second pre-selected CIELAB coordinates L₂*, a₂*, b₂*,C₂*, h₂° resulting from a second colorant being applied onto the outersurface of the subassembly at a second pole thereof.

Meanwhile, the transition color region may have a transitional colorappearance that is comprised of either/each of i) a plurality ofmeasurable CIELAB coordinates L_(Bn)*, a_(Bn)*, h_(Bn)*, C_(Bn)*,h_(Bn)°, wherein “n” represents the number of differing colorappearances within the transition color region; or/and ii) ajuxtaposition of first pre-selected CIELAB coordinates L₁*, a₁*, b₁*,C₁*, h₁° and second pre-selected CIELAB coordinates L₂*, a₂*, b₂*, C₂*,h₂°. In this regard, as stated above, while it is possible for portionsof the transitional color appearance within the transition color regionto comprise instances of solely the first color appearance or solely thesecond color appearance, the transitional color appearance nevercomprises solely the first color appearance adjacent the first colorregion, and also never comprises solely the second color appearanceadjacent the second color region.

Referring to “i)” immediately above, the plurality of measurable CIELABcoordinates L_(Bn)*, a_(Bn)*, b_(Bn)*, C_(Bn)*, h_(Bn)° may result fromblends of the first colorant transitionally overlapping the secondcolorant as well as the second colorant transitionally overlapping thefirst colorant on the outer surface of the cover (or other subassembly)when the first colorant and the second colorant are applied onto theouter surface of the subassembly at the first pole and the second polethereof. There will be instances wherein the first colorant is overlaidwith the second colorant, and other instances wherein the secondcolorant is overlaid with the first colorant.

And the transitional color appearance can be developed such that thedegree of coverage of the first colorant on the outer surface of thesubassembly/cover reduces progressing from adjacent the first colorregion toward the second color region. The blends will therefore becomprised more primarily of the first colorant than of the secondcolorant closer to the first color region. In turn, the degree ofcoverage of the second colorant on the outer surface of thesubassembly/cover can be reduced progressing from adjacent the secondcolor region toward the first color region. In this case, the blendswill be comprised more primarily of the second colorant than of thefirst colorant closer to the second color region.

Juxtaposition occurs when at least one transition dimple has atransition dimple surface that is coated with the first color appearancewith first pre-selected CIELAB coordinates L₁*, a₁*, b₁*, C₁*, h₁° andthe second color appearance with the second pre-selected CIELABcoordinates L₂*, a₂*, b₂*, C₂*, h₂° such that the first color appearanceand second color appearance are juxtaposed on the transition dimplesurface of the transition dimple. In the transition color region, thetransition dimple has a first side and a second side; wherein a firstpole of the first color region is closer to the first side than thesecond side; and wherein a second pole of the second color region iscloser to the second side than the first side; and wherein the firstcolor appearance with first pre-selected CIELAB coordinates L₁*, a₁*,b₁*, C₁*, h₁° on the dimple surface of the transition dimple is locatedon the second side and the second color appearance with the secondpre-selected CIELAB coordinates L₂*, a₂*, b₂*, C₂*, h₂° on the on thedimple surface of the transition dimple is located on the first side.

In the case of juxtaposition of first pre-selected CIELAB coordinatesL₁*, a₁*, b₁*, C₁*, h₁° and second pre-selected CIELAB coordinates L₂*,a₂*, b₂*, C₂*, h₂°, the entire dimple is located within the transitioncolor region only if a different spectrophotometer-measurable colorappearance is detected than that of the adjacent first or second colorregion.

Thus, adjacent the first color region, the transition color regionspectrophotometer-measurably begins if: i) a blend of first pre-selectedCIELAB coordinates L₁*, a₁*, b₁*, C₁*, h₁° and second pre-selectedCIELAB coordinates L₂*, a₂*, b₂*, C₂*, h₂° isspectrophotometer-measurably detected; and/or ii) second pre-selectedCIELAB coordinates L₂*, a₂*, b₂*, C₂*, h₂° isspectrophotometer-measurably detected (due to juxtaposition). Herein,the term spectrophotometer-measurably detected means that aspectrophotometer or other suitable color analysis device inspects thecoating layer at a given location on the golf ball and ascertains colorcoordinates therefor.

Where color analysis reveals a blend, the CIELAB coordinates L_(Bn)*,a_(Bn)*, b_(Bn)*, C_(Bn)*, h_(Bn)° do not match either of firstpre-selected CIELAB coordinates L₁*, a₁*, b₁*, C₁*, h₁° of the firstcolor appearance nor second pre-selected CIELAB coordinates L₂*, a₂*,b₂*, C₂*, h₂° of the second color appearance. Therefore, there arenumerous possible blend CIELAB coordinates L_(Bn)*, a_(Bn)*, b_(Bn)*,C_(Bn)*, h_(Bn)° that can result from the first color appearance beingoverlaid with the second color appearance (and/or vice versa) within thetransition color region of a coating layer formed about the outersurface of a subassembly such as a cover.

For example, in one specific embodiment, a first colorant, having afirst color appearance, may be applied onto the cover surface at a firstpole of a golf ball, while a second (different) colorant having a second(differing) color appearance is applied onto the cover surface at asecond opposing pole of the golf ball. The first colorant coats andcreates a first color region on the cover surface, the second colorantcoats and creates a second color region on the cover surface, and thefirst colorant and second colorant collectively overlay and/or overlapand/or intersect, or otherwise superimpose and/or combine with eachother in many differing ways to create a transition color appearancethat is comprised of a plurality of CIELAB coordinates L_(Bn)*, a_(Bn)*,b_(Bn)*, C_(Bn)*, h_(Bn)° resulting from the first colorant and secondcolorant being provided onto the golf ball outer surface at opposingpoles of the golf ball.

Accordingly, a golf ball of the invention is produced/created having anoverall transitional golf ball color appearance, incorporating a coatinglayer having no visually apparent distinct borders/boundaries betweencolor regions. Instead, desirably, the color appearances of each colorregion may be assessed/ascertained/measured/determined via coloranalysis using, for example, a spectrophotometer such as referencedabove and which may be represented in terms of tristimulus colorimetry.Golf balls of the invention may be better understood by referring toTABLE I below in which color measurements are provided for a first colorregion, a second color region, and a transitional color region of eachof six inventive golf balls Ex. 1, Ex. 2, Ex. 3, Ex. 4, Ex. 5, and Ex. 6as follows:

TABLE I Blue Blue Orange Orange Blue Blue Color CIELAB into into intointo into into Region Parameter Pink Pink Pink Pink Yellow YellowMeasured Measured EX. 1 EX. 2 EX. 3 EX. 4 EX. 5 EX. 6 First L* 64.0765.10 68.99 68.70 67.50 67.38 Color a* −13.27 −16.66 37.04 37.47 −24.64−25.33 Region b* −24.99 −24.76 43.87 43.94 −20.41 −19.01 Measurements C28.29 29.84 57.41 57.95 32.00 31.67 h° 242.03 236.07 49.82 49.54 219.64216.89 Transition L* 60.06 60.73 64.05 63.31 70.74 72.66 Color a* 14.777.49 44.17 45.00 −28.72 −27.50 Region b* −19.61 −20.72 19.84 16.17 4.3617.68 1^(st) location C 24.55 22.07 48.42 47.82 29.05 32.70 Measurementsh° 306.98 290.13 24.19 19.77 171.37 147.26 Transition L* 60.96 59.3064.40 63.18 73.83 73.01 Color a* 7.22 19.59 43.08 44.32 28.48 −27.38Region b* −21.91 −17.45 21.38 16.50 20.23 18.86 2^(nd) location C 23.0726.23 48.09 47.30 34.93 33.24 Measurements h° 288.25 318.30 26.39 20.42144.61 145.45 Transition L* 60.41 60.34 63.49 63.01 75.22 72.61 Color a*10.19 11.22 45.15 44.85 26.27 −28.02 Region b* −20-37 −19.94 16.09 15.5630.08 15.16 3^(rd) location C 22.78 22.88 47.93 47.47 39.94 31.86Measurements h° 296.57 299.37 19.61 19.14 131.13 151.58 Second L* 59.1059.08 59.43 59.58 84.48 84.36 Color a* 47.44 47.44 48.80 48.65 −18.28−18.22 Region b* −9.41 −8.84 −5.52 −3.27 66.55 67.10 Measurements C48.36 48.26 49.11 48.76 69.02 69.53 h° 348.78 349.45 353.54 356.16105.36 105.19

Referring to TABLE I, inventive golf balls Ex. 1, Ex. 2, Ex. 3, Ex. 4,Ex. 5, and Ex. 6 were created by identically placing each of six golfidentical golf balls between a first colorant spray gun and a secondcolorant spray gun. In this experiment, the first colorant spray gun andsecond colorant spray gun were placed at opposing poles of each givengolf ball. Additionally, colorant spray gun pressure and atomizationpressure and nozzle-to-golf ball distance was preset identically foreach pair of first and second colorant spray guns.

The covers of golf balls Ex. 1 and Ex. 2 were spray painted at opposingpoles using Spectracron™ blue primer (available from PPG IndustriesInc.) in the first colorant spray gun and using a Spectracron™ pinkprimer in the second colorant spray gun.

Meanwhile, the covers of each of golf balls Ex. 3 and Ex. 4 were paintedat opposing poles using orange Spectracron™ primer in the first colorantspray gun and pink Spectracron™ primer in the second colorant spray gun.

In turn, the covers of each of golf balls Ex. 5 and Ex. 6 were paintedat opposing poles using the blue Spectracron™ primer in the firstcolorant spray gun and yellow Spectracron™ primer in the second colorantspray gun.

Resulting inventive golf balls Ex. 1, Ex. 2, Ex. 3, Ex. 4, Ex. Ex. 5,and Ex. 6 of TABLE I each thereby had a coating layer formed entirelyabout its corresponding cover comprised of a first color region, asecond color region, and a transitional color region that wastransitionally disposed between the first color region and the secondcolor region and extended about the entire circumference of itsrespective cover. Color appearance measurements were ascertained in eachfirst color region, second color region and transitional color region ofinventive golf balls Ex. 1, Ex. 2, Ex. 3, Ex. 4, Ex. 5, and Ex. 6 byplacing each in a Gretag Macbeth CE 7000A spectrophotometer underilluminant D65, with a 10° standard observer. For each golf ball, asingle color measurement was taken for each of the first colorappearance of the first color region and the second color appearance ofsecond color region; and three color measurements were taken for thetransitional color appearance within the transition color region. All ofthese measurements are recorded in TABLE I.

It should be noted that while inventive golf balls Ex. 1, Ex. 2, Ex. 3,Ex. 4, Ex. 5, and Ex. 6 of TABLE I were created using two colorant sprayguns, embodiments are also envisioned wherein greater than two colorantspray guns may be used and/or wherein the colorant spray guns may bepositioned less than opposingly, as long as doing so creates atransitional color region between two or more color regions such as afirst color region and a second color region.

Additionally, it should be noted that the specific settings selected foreach of colorant spray gun pressure, atomization pressure andnozzle-to-golf ball distance may vary depending, for example, on thedispense time as well as on the coverage desired on the golf ball foreach of the first colorant and the second colorant and also dependingthe viscosity of the colorant being used.

In non-limiting examples, colorant spray gun pressure may be about 50-70psi, atomization pressure may be about 25-50 psi, and nozzle-to-golfball distance may be about 2.5 to 3.5 inches.

And while example golf balls of the invention Ex. 1, Ex. 2, Ex. 3, Ex.4, Ex. 5, and Ex. 6 of TABLE I were created using liquid primers, it isenvisioned that any suitable known coloring agents/colorants such as butnot limited to pigments, dyes, tints, inks, structured colorants, etc.may be used. Furthermore, embodiments are envisioned wherein methodsother than using colorant spray guns are used for creating a golf ballof the invention, such as wherein the first color appearance, the secondcolor appearance, and the transition color appearance are created byspraying, splattering, sputtering, wiping, and/or brushing a firstcolorant onto the outer surface of the cover at a first pole; andspraying, splattering, sputtering, wiping, and/or brushing a secondcolorant onto the outer surface of the cover at an opposing pole of thecover.

Embodiments are envisioned wherein a color detection device may be usedto measure the surface areas of each color region. For example, thecolor detection device may be used to detect where on the coating layerthe first color appearance of the first color region ends and thetransition color appearance of the transition color region begins. Insome such embodiments, the transition color region may have a surfacearea SA_(TCR) and the coating layer may have a total surface areaSA_(CL) such that a ratio of SA_(TCR):SA_(CL) is at least 0.10. Inanother such embodiment, the transition color region may have a surfacearea SA_(TCR) and the coating layer may have a total surface areaSA_(CL) such that a ratio of SA_(TCR) to SA_(CL) is:

0.10<SA _(TCR) :SA _(CL)≤0.50.

In a different such embodiment, the first color region may have asurface area SA_(FCR) and the second color region may have a surfacearea SA_(SCR) and the coating layer may have a total surface areaSA_(CL) such that each of a ratio of SA_(FCR) to SA_(CL) and a ratio ofSA_(SCR):SA_(CL) is at least 0.30.

In one embodiment, SA_(FCR) is the same as SA_(SCR). In anotherembodiment, SA_(FCR) is greater than SA_(SCR). In yet anotherembodiment, SA_(FCR) is less than SA_(SCR) of the second color region.

Embodiments are also envisioned wherein algorithmic coating applicationsmay be implemented in making golf balls of the invention so that eachresulting golf ball has a different custom overall transitional colorappearance. Toward this end, lines of code can be written so thatsoftware pulls from a database one of the numerous possible ways thatthe first color appearance and the second color appearance can form onthe surface of the subassembly within the transition color region andcollectively produce a transitional color appearance on the outersurface of a subassembly within the transition color region.

Finished golf balls of the invention may have any number of layers, withthe one limitation being that at least one coating layer is disposedentirely about an outer surface of a subassembly (such as a core and acover) wherein the coating layer has a first color region having a firstcolor appearance; a second color region having a second color appearancethat is different than the first color appearance; and a transitioncolor region that is transitionally disposed between each of the firstcolor region and the second color region and comprises the first colorappearance and the second color appearance. In many embodiments, thetransitional color region is not only transitionally disposed betweenthe first color region and the second color region but is meanwhile alsodisposed circumferentially about the outer surface of the subassembly.

The coating layer may comprise any colorant that may be applied orotherwise provided about the outer surface of the cover or othersubassembly being coated to create the first color region, having afirst color appearance; the second color region, having a second colorappearance that is different than the first color appearance; and thetransition color region that is transitionally disposed between each ofthe first color region and the second color region and comprises thefirst color appearance and the second color appearance as described andclaimed herein.

The coating layer may have any known thickness that can be so applied orotherwise provided. For example, each coating layer may have a thicknessof from about 0.1 μm to about 50 μm, or from about 0.1 μm to about 25μm, or from about 0.1 μm to about 14 μm, or from about 2 μm to about 9μm, for example. Or, one or more such inventive coating layers may beformed about the outer surface of a cover or other subassembly and havea combined thickness of from about 0.1 μm to about 100 μm, or from about2 μm to about 50 μm, or from about 2 μm to about 30 μm.

It is also envisioned that one or more additional coating layers (clear,clear-colored, and/or translucent) may be applied about an outer surfaceof the coating layer of a golf ball of the invention.

In golf balls of the invention, the surface/substrate/layer onto andabout which the coating layer is formed may comprise any known golf ballmaterial such as but not limited to ionomers, HNPs, polyurethanes(thermoset, thermoplastic), polyureas, polyurethane/polyurea hybids,polybutadienes, plasticized thermoplastics, polyalkenamer compositions,polyester-based thermoplastic elastomers containing plasticizers,transparent or plasticized polyamides, thiolene compositions, poly-amideand anhydride-modified polyolefins, organic acid-modified polymers, andthe like.

Otherwise, a novel golf ball produced by a method of the invention mayinclude a core and a cover, although embodiments are indeed envisionedwherein the coating layer serves as a different layer such as anintermediate of inner cover layer.

That being said, a core in a golf ball of the invention may be a singlecore or be multi-layered. For example, a multi-layer core may comprisean inner core (sometimes also referred to as a center or spherical innercore) and an outer core layer.

Additionally, one or more intermediate core layers may be disposedbetween the core and the outer core layer. Intermediate layers generallycomprise a casing layers, moisture barrier layers, film layers, coatinglayers, and/or inner cover layers. Outer core layers are even sometimesreferred to as intermediate layers.

The core often comprises rubber, although embodiments are indeedenvisioned wherein any material known in the golf ball art may be usedin the core to target desired golf ball properties and playingcharacteristics. Thus, materials typically used as an intermediate layeror an outermost cover layer may sometimes be used as a core material.

Non-limiting examples of suitable rubber materials includepolybutadiene, ethylene-propylene rubber, ethylene-propylene-dienerubber, polyisoprene, styrene-butadiene rubber, polyalkenamers, butylrubber, halobutyl rubber, and/or polystyrene elastomers. In general,polybutadiene is a homopolymer of 1,3-butadiene. The double bonds in the1,3-butadiene monomer are attacked by catalysts to grow the polymerchain and form a polybutadiene polymer having a desired molecularweight. Any suitable catalyst may be used to synthesize thepolybutadiene rubber depending upon the desired properties. Normally, atransition metal complex (for example, neodymium, nickel, or cobalt) oran alkyl metal such as alkyllithium is used as a catalyst. Othercatalysts include, but are not limited to, aluminum, boron, lithium,titanium, and combinations thereof. The catalysts produce polybutadienerubbers having different chemical structures.

In a cis-bond configuration, the main internal polymer chain of thepolybutadiene appears on the same side of the carbon-carbon double bondcontained in the polybutadiene. In a trans-bond configuration, the maininternal polymer chain is on opposite sides of the internalcarbon-carbon double bond in the polybutadiene. The polybutadiene rubbercan have various combinations of cis- and trans-bond structures.

A preferred polybutadiene rubber has a 1,4 cis-bond content of at least40%, preferably greater than 80%, and more preferably greater than 90%.In general, polybutadiene rubbers having a high 1,4 cis-bond contenthave high tensile strength. The polybutadiene rubber may have arelatively high or low Mooney viscosity.

Examples of commercially-available polybutadiene rubbers that can beused in accordance with this invention, include, but are not limited to,BR 01 and BR 1220, available from BST Elastomers of Bangkok, Thailand;SE BR 1220LA and SE BR1203, available from DOW Chemical Co of Midland,Mich.; BUDENE 1207, 1207s, 1208, and 1280 available from Goodyear, Incof Akron, Ohio; BR 01, 51 and 730, available from Japan Synthetic Rubber(JSR) of Tokyo, Japan; BUNA CB 21, CB 22, CB 23, CB 24, CB 25, CB 29MES, CB 60, CB Nd 60, CB 55 NF, CB 70 B, CB KA 8967, and CB 1221,available from Lanxess Corp. of Pittsburgh. Pennsylvania; BR1208,available from LG Chemical of Seoul, South Korea; UBEPOL BR130B, BR150,BR150B, BR150L, BR230, BR360L, BR710, and VCR617, available from UBEIndustries, Ltd. of Tokyo, Japan; EUROPRENE NEOCIS BR 60, INTENE 60 AFand P30AF, and EUROPRENE BR HV80, available from Polimeri Europa ofRome, Italy; AFDENE 50 and NEODENE BR40, BR45, BR50 and BR60, availablefrom Karbochem (PTY) Ltd. of Bruma, South Africa; KBR 01, NdBr 40,NdBR-45, NdBr 60, KBR 710S, KBR 710H, and KBR 750, available from KumhoPetrochemical Co., Ltd. Of Seoul, South Korea; and DIENE 55NF, 70AC, and320 AC, available from Firestone Polymers of Akron, Ohio.

To form the core, the polybutadiene rubber is used in an amount of atleast about 5% by weight based on total weight of composition and isgenerally present in an amount of about 5% to about 100%, or an amountwithin a range having a lower limit of 5% or 10% or 20% or 30% or 40% or50% and an upper limit of 55% or 60% or 70% or 80% or 90% or 95% or100%. In general, the concentration of polybutadiene rubber is about 45to about 95 weight percent. Preferably, the rubber material used to formthe core layer comprises at least 50% by weight, and more preferably atleast 70% by weight, polybutadiene rubber.

The rubber compositions used in connection with the methods and golfballs of this invention may be peroxide-cured without inhibiting cure.Suitable organic peroxides include, but are not limited to, dicumylperoxide; n-butyl-4,4-di(t-butylperoxy) valerate;1,1-di(t-butylperoxy)3,3,5-trimethylcyclohexane;2,5-dimethyl-2,5-di(t-butylperoxy) hexane; di-t-butyl peroxide;di-t-amyl peroxide; t-butyl peroxide; t-butyl cumyl peroxide;2,5-dimethyl-2,5-di(t-butylperoxy)hexyne-3;di(2-t-butyl-peroxyisopropyl)benzene; dilauroyl peroxide; dibenzoylperoxide; t-butyl hydroperoxide; and combinations thereof. In aparticular embodiment, the free radical initiator is dicumyl peroxide,including, but not limited to Perkadox® BC, commercially available fromAkzo Nobel.

Peroxide free-radical initiators are generally present in the rubbercomposition in an amount of at least 0.05 parts by weight per 100 partsof the total rubber, or an amount within the range having a lower limitof 0.05 parts or 0.1 parts or 1 part or 1.25 parts or 1.5 parts or 2.5parts or 5 parts by weight per 100 parts of the total rubbers, and anupper limit of 2.5 parts or 3 parts or 5 parts or 6 parts or 10 parts or15 parts by weight per 100 parts of the total rubber. Concentrations arein parts per hundred (phr) unless otherwise indicated. As used herein,the term, “parts per hundred,” also known as “phr” or “pph” is definedas the number of parts by weight of a particular component present in amixture, relative to 100 parts by weight of the polymer component.Mathematically, this can be expressed as the weight of an ingredientdivided by the total weight of the polymer, multiplied by a factor of100.

Suitable co-agents, where desired, may include, but are not limited to,metal salts of unsaturated carboxylic acids having from 3 to 8 carbonatoms; unsaturated vinyl compounds and polyfunctional monomers (e.g.,trimethylolpropane trimethacrylate); phenylene bismaleimide; andcombinations thereof. Particular examples of suitable metal saltsinclude, but are not limited to, one or more metal salts of acrylates,diacrylates, methacrylates, and dimethacrylates, wherein the metal isselected from magnesium, calcium, zinc, aluminum, lithium, and nickel.In a particular embodiment, the co-agent is selected from zinc salts ofacrylates, diacrylates, methacrylates, and dimethacrylates.

In another particular embodiment, the agent is zinc diacrylate (ZDA).When the co-agent is zinc diacrylate and/or zinc dimethacrylate, theco-agent is typically included in the rubber composition in an amountwithin the range having a lower limit of 1 or 5 or 10 or 15 or 19 or 20parts by weight per 100 parts of the total rubber, and an upper limit of24 or 25 or 30 or 35 or 40 or 45 or 50 or 60 parts by weight per 100parts of the base rubber.

Radical scavengers such as a halogenated organosulfur or metal saltthereof, organic disulfide, or inorganic disulfide compounds may beadded to the rubber composition. These compounds also may function as“soft and fast agents.” As used herein, “soft and fast agent” means anycompound or a blend thereof that is capable of making a core: 1) softer(having a lower compression) at a constant “coefficient of restitution”(COR); and/or 2) faster (having a higher COR at equal compression), whencompared to a core equivalently prepared without a soft and fast agent.

Preferred halogenated organosulfur compounds include, but are notlimited to, pentachlorothiophenol (PCTP) and salts of PCTP such as zincpentachlorothiophenol (ZnPCTP). Using PCTP and ZnPCTP in golf ball innercores helps produce softer and faster inner cores. The PCTP and ZnPCTPcompounds help increase the resiliency and the coefficient ofrestitution of the core. In a particular embodiment, the soft and fastagent is selected from ZnPCTP, PCTP, ditolyl disulfide, diphenyldisulfide, dixylyl disulfide, 2-nitroresorcinol, and combinationsthereof.

The rubber compositions of the present invention also may include“fillers,” which are added to adjust the density and/or specific gravityof the material. Suitable fillers include, but are not limited to,polymeric or mineral fillers, metal fillers, metal alloy fillers, metaloxide fillers and carbonaceous fillers. The fillers can be in anysuitable form including, but not limited to, flakes, fibers, whiskers,fibrils, plates, particles, and powders. Rubber regrind, which isground, recycled rubber material (for example, ground to about 30 meshparticle size) obtained from discarded rubber golf ball cores, also canbe used as a filler. The amount and type of fillers utilized aregoverned by the amount and weight of other ingredients in the golf ball,since a maximum golf ball weight of 45.93 g (1.62 ounces) has beenestablished by the United States Golf Association (US GA).

Suitable polymeric or mineral fillers that may be added to the rubbercomposition include, for example, precipitated hydrated silica, clay,talc, asbestos, glass fibers, aramid fibers, mica, calcium metasilicate,barium sulfate, zinc sulfide, lithopone, silicates, silicon carbide,tungsten carbide, diatomaceous earth, polyvinyl chloride, carbonatessuch as calcium carbonate and magnesium carbonate. Suitable metalfillers include titanium, tungsten, aluminum, bismuth, nickel,molybdenum, iron, lead, copper, boron, cobalt, beryllium, zinc, and tin.Suitable metal alloys include steel, brass, bronze, boron carbidewhiskers, and tungsten carbide whiskers. Suitable metal oxide fillersinclude zinc oxide, iron oxide, aluminum oxide, titanium oxide,magnesium oxide, and zirconium oxide. Suitable particulate carbonaceousfillers include graphite, carbon black, cotton flock, natural bitumen,cellulose flock, and leather fiber. Micro balloon fillers such as glassand ceramic, and fly ash fillers can also be used.

In a particular aspect of this embodiment, the rubber compositionincludes filler(s) selected from carbon black, nanoclays (e.g.,Cloisite® and Nanofil® nanoclays, commercially available from SouthernClay Products, Inc., and Nanomax® and Nanomer® nanoclays, commerciallyavailable from Nanocor, Inc.), talc (e.g., Luzenac HAR® high aspectratio talcs, commercially available from Luzenac America, Inc.), glass(e.g., glass flake, milled glass, and microglass), mica and mica-basedpigments (e.g., Iriodin® pearl luster pigments, commercially availablefrom The Merck Group), and combinations thereof. In a particularembodiment, the rubber composition is modified with organic fibermicropulp.

In addition, the rubber compositions may include antioxidants to preventthe breakdown of the elastomers. Also, processing aids such as highmolecular weight organic acids and salts thereof, may be added to thecomposition. In a particular embodiment, the total amount of additive(s)and filler(s) present in the rubber composition is 15 wt % or less, or12 wt % or less, or 10 wt % or less, or 9 wt % or less, or 6 wt % orless, or 5 wt % or less, or 4 wt % or less, or 3 wt % or less, based onthe total weight of the rubber composition.

The polybutadiene rubber material (base rubber) may be blended withother elastomers in accordance with this invention. Other elastomersinclude, but are not limited to, polybutadiene, polyisoprene, ethylenepropylene rubber (“EPR”), styrene-butadiene rubber, styrenic blockcopolymer rubbers (such as “SI”, “SIS”, “SB”, “SBS”, “SIBS”, and thelike, where “S” is styrene, “I” is isobutylene, and “B” is butadiene),polyalkenamers such as, for example, polyoctenamer, butyl rubber,halobutyl rubber, polystyrene elastomers, polyethylene elastomers,polyurethane elastomers, polyurea elastomers, metallocene-catalyzedelastomers and plastomers, copolymers of isobutylene and p-alkylstyrene,halogenated copolymers of isobutylene and p-alkylstyrene, copolymers ofbutadiene with acrylonitrile, polychloroprene, alkyl acrylate rubber,chlorinated isoprene rubber, acrylonitrile chlorinated isoprene rubber,and combinations of two or more thereof.

For example, in one embodiment, the elastomer composition may comprisei) about 50% to about 95% by weight of a non-metallocene catalyzedpolybutadiene rubber; and ii) about 5 to about 50% by weight of ametallocene-catalyzed polybutadiene rubber; wherein examples of suitablenon-metallocene catalysts (may be referred to as Ziegler-Nattacatalysts) include neodymium, nickel, cobalt, titanium, aluminum, boron,and alkylithium-based catalysts, and combinations thereof; and examplesof suitable metallocene catalysts are complexes based on metals such ascobalt, gadolinium, iron, lanthanum, neodymium, nickel, praseodymium,samarium, titanium, vanadium, zirconium; and combinations thereof.

The polymers, free-radical initiators, filler, cross-linking agents, andany other materials used in forming either the golf ball center or anyof the core, in accordance with invention, may be combined to form amixture by any type of mixing known to one of ordinary skill in the art.Suitable types of mixing include single pass and multi-pass mixing, andthe like. The cross-linking agent, and any other optional additives usedto modify the characteristics of the golf ball center or additionallayer(s), may similarly be combined by any type of mixing.

A single-pass mixing process where ingredients are added sequentially ispreferred, as this type of mixing tends to increase efficiency andreduce costs for the process. The preferred mixing cycle is single stepwherein the polymer, cis-to-trans catalyst, filler, zinc diacrylate, andperoxide are added in sequence.

In one embodiment, the core may be formed of a rubber compositioncomprising a material selected from the group of natural and syntheticrubbers including, but not limited to, polybutadiene, polyisoprene,ethylene propylene rubber (“EPR”), ethylene-propylene-diene (“EPDM”)rubber, styrene-butadiene rubber, styrenic block copolymer rubbers (suchas “SI”, “SIS”, “SB”, “SBS”, “SIBS”, and the like, where “S” is styrene,“I” is isobutylene, and “B” is butadiene), polyalkenamers such as, forexample, polyoctenamer, butyl rubber, halobutyl rubber, polystyreneelastomers, polyethylene elastomers, polyurethane elastomers, polyureaelastomers, metallocene-catalyzed elastomers and plastomers, copolymersof isobutylene and p-alkylstyrene, halogenated copolymers of isobutyleneand p-alkylstyrene, copolymers of butadiene with acrylonitrile,polychloroprene, alkyl acrylate rubber, chlorinated isoprene rubber,acrylonitrile chlorinated isoprene rubber, and combinations of two ormore thereof.

The core structure may be surface-treated to increase the adhesionbetween its outer surface and the next layer that will be applied overthe core. Such surface-treatment may include mechanically orchemically-abrading the outer surface of the core. For example, the coremay be subjected to corona-discharge, plasma-treatment, silane-dipping,or other treatment methods known to those in the art.

Meanwhile, materials often used in the intermediate layer include, forexample, an ionomer composition comprising an ethylene acid copolymercontaining acid groups that are at least partially neutralized. Suitableethylene acid copolymers that may be used to form the intermediatelayers are generally referred to as copolymers of ethylene; C₃ to C₈ α,β-ethylenically unsaturated mono-or dicarboxylic acid; and optionalsoftening monomer. These ethylene acid copolymer ionomers also can beused to form the inner core and outer core layers as described above.

Suitable ionomer compositions include partially-neutralized ionomers andhighly-neutralized ionomers (HNPs), including ionomers formed fromblends of two or more partially-neutralized ionomers, blends of two ormore highly-neutralized ionomers, and blends of one or morepartially-neutralized ionomers with one or more highly-neutralizedionomers. For purposes of the present disclosure, “HNP” refers to anacid copolymer after at least 70% of all acid groups present in thecomposition are neutralized. Preferred ionomers are salts of O/X- andO/X/Y-type acid copolymers, wherein O is an α-olefin, X is a C₃-C₈α,β-ethylenically unsaturated carboxylic acid, and Y is a softeningmonomer. O is preferably selected from ethylene and propylene. X ispreferably selected from methacrylic acid, acrylic acid, ethacrylicacid, crotonic acid, and itaconic acid. Methacrylic acid and acrylicacid are particularly preferred. Y is preferably selected from (meth)acrylate and alkyl (meth) acrylates wherein the alkyl groups have from 1to 8 carbon atoms, including, but not limited to, n-butyl (meth)acrylate, isobutyl (meth) acrylate, methyl (meth) acrylate, and ethyl(meth) acrylate.

Preferred O/X and O/X/Y-type copolymers include, without limitation,ethylene acid copolymers, such as ethylene/(meth)acrylic acid,ethylene/(meth)acrylic acid/maleic anhydride, ethylene/(meth)acrylicacid/maleic acid mono-ester, ethylene/maleic acid, ethylene/maleic acidmono-ester, ethylene/(meth)acrylic acid/n-butyl (meth)acrylate,ethylene/(meth)acrylic acid/iso-butyl (meth)acrylate,ethylene/(meth)acrylic acid/methyl (meth)acrylate,ethylene/(meth)acrylic acid/ethyl (meth)acrylate terpolymers, and thelike. The term, “copolymer,” as used herein, includes polymers havingtwo types of monomers, those having three types of monomers, and thosehaving more than three types of monomers. Preferred α, β-ethylenicallyunsaturated mono- or dicarboxylic acids are (meth) acrylic acid,ethacrylic acid, maleic acid, crotonic acid, fumaric acid, itaconicacid. (Meth) acrylic acid is most preferred. As used herein, “(meth)acrylic acid” means methacrylic acid and/or acrylic acid. Likewise,“(meth) acrylate” means methacrylate and/or acrylate.

In a particularly preferred version, highly neutralized E/X- andE/X/Y-type acid copolymers, wherein E is ethylene, X is a C₃-C₈ α,β-ethylenically unsaturated carboxylic acid, and Y is a softeningmonomer are used. X is preferably selected from methacrylic acid,acrylic acid, ethacrylic acid, crotonic acid, and itaconic acid.Methacrylic acid and acrylic acid are particularly preferred. Y ispreferably an acrylate selected from alkyl acrylates and aryl acrylatesand preferably selected from (meth) acrylate and alkyl (meth) acrylateswherein the alkyl groups have from 1 to 8 carbon atoms, including, butnot limited to, n-butyl (meth) acrylate, isobutyl (meth) acrylate,methyl (meth) acrylate, and ethyl (meth) acrylate. Preferred E/X/Y-typecopolymers are those wherein X is (meth) acrylic acid and/or Y isselected from (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth)acrylate, methyl (meth) acrylate, and ethyl (meth) acrylate. Morepreferred E/X/Y-type copolymers are ethylene/(meth) acrylic acid/n-butylacrylate, ethylene/(meth) acrylic acid/methyl acrylate, andethylene/(meth) acrylic acid/ethyl acrylate.

The amount of ethylene in the acid copolymer is typically at least 15wt. %, preferably at least 25 wt. %, more preferably least 40 wt. %, andeven more preferably at least 60 wt. %, based on total weight of thecopolymer. The amount of C₃ to C₈ α, β-ethylenically unsaturated mono-ordicarboxylic acid in the acid copolymer is typically from 1 wt. % to 35wt. %, preferably from 5 wt. % to 30 wt. %, more preferably from 5 wt. %to 25 wt. %, and even more preferably from 10 wt. % to 20 wt. %, basedon total weight of the copolymer. The amount of optional softeningcomonomer in the acid copolymer is typically from 0 wt. % to 50 wt. %,preferably from 5 wt. % to 40 wt. %, more preferably from 10 wt. % to 35wt. %, and even more preferably from 20 wt. % to 30 wt. %, based ontotal weight of the copolymer. “Low acid” and “high acid” ionomericpolymers, as well as blends of such ionomers, may be used. In general,low acid ionomers are considered to be those containing 16 wt. % or lessof acid moieties, whereas high acid ionomers are considered to be thosecontaining greater than 16 wt. % of acid moieties.

The various O/X, E/X, O/X/Y, and E/X/Y-type copolymers are at leastpartially neutralized with a cation source, optionally in the presenceof a high molecular weight organic acid, such as those disclosed in U.S.Pat. No. 6,756,436, the entire disclosure of which is herebyincorporated herein by reference. The acid copolymer can be reacted withthe optional high molecular weight organic acid and the cation sourcesimultaneously, or prior to the addition of the cation source. Suitablecation sources include, but are not limited to, metal ion sources, suchas compounds of alkali metals, alkaline earth metals, transition metals,and rare earth elements; ammonium salts and monoamine salts; andcombinations thereof. Preferred cation sources are compounds ofmagnesium, sodium, potassium, cesium, calcium, barium, manganese,copper, zinc, lead, tin, aluminum, nickel, chromium, lithium, and rareearth metals.

Additional suitable materials for golf ball layers include but are notlimited to ionomers (e.g. Surlyn®, HNPs, etc.) and blends thereof. Theionomer may include, for example, partially-neutralized ionomers andhighly-neutralized ionomers (HNPs), including ionomers formed fromblends of two or more partially-neutralized ionomers, blends of two ormore highly-neutralized ionomers, and blends of one or morepartially-neutralized ionomers with one or more highly-neutralizedionomers.

Ionomers, are typically ethylene/acrylic acid copolymers orethylene/acrylic acid/acrylate terpolymers in which some or all of theacid groups are neutralized with metal cations such as na, li, mg,and/or zn. Non-limiting examples of commercially available ionomerssuitable for use with the present invention include for example SURLYNs®from DuPont and Ioteks® from Exxon. SURLYN® 8940 (Na), SURLYN® 9650(Zn), and SURLYN® 9910 (Zn) are examples of low acid ionomer resins withthe acid groups that have been neutralized to a certain degree with acation. More examples of suitable low acid ionomers, e.g., Escor®4000/7030 and Escor® 900/8000, are disclosed in U.S. Pat. Nos. 4,911,451and 4,884,814, the disclosures of which are incorporated by referenceherein. High acid ionomer resins include SURLYN(® 8140 (Na) and SURLYN®8546 (Li), which have an methacrylic acid content of about 19 percent.The acid groups of these high acid ionomer resins that have beenneutralized to a certain degree with the designated cation.

Ionomers may encompass those polymers obtained by copolymerization of anacidic or basic monomer, such as alkyl (meth)acrylate, with at least oneother comonomer, such as an olefin, styrene or vinyl acetate, followedby at least partial neutralization. Alternatively, acidic or basicgroups may be incorporated into a polymer to form an ionomer by reactingthe polymer, such as polystyrene or a polystyrene copolymer including ablock copolymer of polystyrene, with a functionality reagent, such as acarboxylic acid or sulfonic acid, followed by at least partialneutralization. Suitable neutralizing sources include cations fornegatively charged acidic groups and anions for positively charged basicgroups.

For example, ionomers may be obtained by providing a cross metallic bondto polymers of monoolefin with at least one member selected from thegroup consisting of unsaturated mono- or di-carboxylic acids having 3 to12 carbon atoms and esters thereof (the polymer contains about 1 percentto about 50 percent by weight of the unsaturated mono- or di-carboxylicacid and/or ester thereof). In one embodiment, the ionomer is an E/X/Ycopolymers where E is ethylene, X is a softening comonomer, such asacrylate or methacrylate, present in 0 percent to about 50 percent byweight of the polymer (preferably 0 weight percent to about 25 weightpercent, most preferably 0 weight percent to about 20 weight percent),and Y is acrylic or methacrylic acid present in about 5 to about 35weight percent of the polymer, wherein the acid moiety is neutralizedabout 1 percent to about 100 percent (preferably at least about 40percent, most preferably at least about 60 percent) to form an ionomerby a cation such as lithium, sodium, potassium, magnesium, calcium,barium, lead, tin, zinc, or aluminum, or a combination of such cations.

Any of the acid-containing ethylene copolymers discussed above may beused to form an ionomer according to the present invention. In addition,the ionomer may be a low acid or high acid ionomer. As detailed above, ahigh acid ionomer may be a copolymer of an olefin, e.g., ethylene, andat least 16 weight percent of an α,β-ethylenically unsaturatedcarboxylic acid, e.g., acrylic or methacrylic acid, wherein about 10percent to about 100 percent of the carboxylic acid groups areneutralized with a metal ion. In contrast, a low acid ionomer containsabout 15 weight percent of the α,β-ethylenically unsaturated carboxylicacid.

Suitable commercially available ionomer resins include SURLYNs® (DuPont)and Ioteks® (Exxon). Other suitable ionomers for use in the blends ofthe present invention include polyolefins, polyesters, polystyrenes,SBS, SEBS, and polyurethanes, in the form of homopolymers, copolymers,or block copolymer ionomers.

The ionomers may also be blended with highly neutralized polymers (HNP).As used herein, a highly neutralized polymer has greater than about 70percent of the acid groups neutralized. In one embodiment, about 80percent or greater of the acid groups are neutralized. In anotherembodiment, about 90 percent or greater of the acid groups areneutralized. In still another embodiment, the HNP is a fully neutralizedpolymers, i.e., all of the acid groups (100 percent) in the polymercomposition are neutralized.

Suitable HNPs include, but are not limited to, polymers containingα,β-unsaturated carboxylic acid groups, or the salts thereof, that havebeen highly neutralized by organic fatty acids. Such HNPs arecommercially available from DuPont under the trade name HPF, e.g., HPF1000 and HPF 2000. The HNP can also be formed using an oxa-containingcompound as a reactive processing aid to avoid processing problems, asdisclosed in U.S. Patent Publication No. 2003/0225197. In particular, anHNP can include a thermoplastic resin component having an acid or ionicgroup, i.e., an acid polymer or partially neutralized polymer, combinedwith an oxa acid, an oxa salt, an oxa ester, or combination thereof andan inorganic metal compound or organic amine compound. As used herein, apartially neutralized polymer should be understood to mean polymers withabout 10 to about 70 percent of the acid groups neutralized. Forexample, the HNP can includes about 10 percent to about 30 percent byweight of at least one oxa acid, about 70 percent to about 90 percent byweight of at least one thermoplastic resin component, and about 2percent to about 6 percent by weight of an inorganic metal compound,organic amine, or a combination thereof.

In addition, the HNP can be formed from an acid copolymer that isneutralized by one or more amine-based or ammonium-based components, ormixtures thereof, as disclosed in co-pending U.S. patent applicationSer. No. 10/875,725, filed Jun. 25, 2004, entitled “Golf BallCompositions Neutralized with Ammonium-Based and Amine-Based Compounds,”which is incorporated in its entirety by reference herein.

Furthermore, those of ordinary skill in the art will appreciate that theHNPs may be neutralized using one or more of the above methods. Forexample, an acid copolymer that is partially or highly neutralized in amanner described above may be subjected to additional neutralizationusing more traditional processes, e.g., neutralization with salts oforganic fatty acids and/or a suitable cation source.

In a particular embodiment, ionomers may be selected from DuPont® HPFESX 367, HPF 1000, HPF 2000, HPF AD1035, HPF AD1035 Soft, HPF AD1040,and AD1172 ionomers, commercially available from E. I. du Pont deNemours and Company. The coefficient of restitution (“COR”),compression, and surface hardness of each of these materials, asmeasured on 1.55″ injection molded spheres aged two weeks at 23° C./50%RH, are given in Table 1 below.

TABLE 1 Solid Solid Sphere Sphere Solid Sphere Shore D Example CORCompression Surface Hardness HPF 1000 0.830 115 54 HPF 2000 0.860 90 47HPF AD1035 0.820 63 42 HPF AD1035 Soft 0.780 33 35 HPF AD 1040 0.855 13560 HPF AD1172 0.800 32 37

Additional materials generally used to form intermediate layers includebut are not limited to the following polymers (including homopolymers,copolymers, and derivatives thereof: (a) polyester, particularly thosemodified with a compatibilizing group such as sulfonate or phosphonate,including modified poly(ethylene terephthalate), modified poly(butyleneterephthalate), modified poly(propylene terephthalate), modifiedpoly(trimethylene terephthalate), modified poly(ethylene naphthenate),and those disclosed in U.S. Pat. Nos. 6,353,050, 6,274,298, and6,001,930, the entire disclosures of which are hereby incorporatedherein by reference, and blends of two or more thereof; (b) polyamides,polyamide-ethers, and polyamide-esters, and those disclosed in U.S. Pat.Nos. 6,187,864, 6,001,930, and 5,981,654, the entire disclosures ofwhich are hereby incorporated herein by reference, and blends of two ormore thereof; (c) polyurethanes, polyureas, polyurethane-polyureahybrids, and blends of two or more thereof; (d) fluoropolymers, such asthose disclosed in U.S. Pat. Nos. 5,691,066, 6,747,110 and 7,009,002,the entire disclosures of which are hereby incorporated herein byreference, and blends of two or more thereof; (e) polystyrenes, such aspoly(styrene-co-maleic anhydride), acrylonitrile-butadiene-styrene,poly(styrene sulfonate), polyethylene styrene, and blends of two or morethereof; (f) polyvinyl chlorides and grafted polyvinyl chlorides, andblends of two or more thereof; (g) polycarbonates, blends ofpolycarbonate/acrylonitrile-butadiene-styrene, blends ofpolycarbonate/polyurethane, blends of polycarbonate/polyester, andblends of two or more thereof; (h) polyethers, such as polyaryleneethers, polyphenylene oxides, block copolymers of alkenyl aromatics withvinyl aromatics and polyamicesters, and blends of two or more thereof;(i) polyimides, polyetherketones, polyamideimides, and blends of two ormore thereof; and (j) polycarbonate/polyester copolymers and blends.

Intermediate layer(s) may also be formed, at least in part, fromprimarily or fully non-ionomeric thermoplastic materials, polyurethanes,polyureas, polyurethane/polyurea hybrids, acrylic resins and blendsthereof, olefinic thermoplastic rubbers, block copolymers of styrene andbutadiene, isoprene or ethylene-butylene rubber, copoly(ether-amide),polyphenylene oxide resins or blends thereof, and thermoplasticpolyesters. And as with the core, embodiments are envisioned wherein atleast one intermediate layer is formed from a material commonly used ina core and/or cover layer.

Polyurethanes are often used as cover materials. In general,polyurethanes contain urethane linkages formed by reacting an isocyanategroup (—N═C═O) with a hydroxyl group (OH). The polyurethanes areproduced by the reaction of a multi-functional isocyanate (NCO—R—NCO)with a long-chain polyol having terminal hydroxyl groups (OH—OH) in thepresence of a catalyst and other additives. The chain length of thepolyurethane prepolymer is extended by reacting it with short-chaindiols (OH—R′—OH). The resulting polyurethane has elastomeric propertiesbecause of its “hard” and “soft” segments, which are covalently bondedtogether. This phase separation occurs because the mainly non-polar, lowmelting soft segments are incompatible with the polar, high melting hardsegments. The hard segments, which are formed by the reaction of thediisocyanate and low molecular weight chain-extending diol, arerelatively stiff and immobile. The soft segments, which are formed bythe reaction of the diisocyanate and long chain diol, are relativelyflexible and mobile. Because the hard segments are covalently coupled tothe soft segments, they inhibit plastic flow of the polymer chains, thuscreating elastomeric resiliency.

By the term, “isocyanate compound” as used herein, it is meant anyaliphatic or aromatic isocyanate containing two or more isocyanatefunctional groups. The isocyanate compounds can be monomers or monomericunits, because they can be polymerized to produce polymeric isocyanatescontaining two or more monomeric isocyanate repeat units. The isocyanatecompound may have any suitable backbone chain structure includingsaturated or unsaturated, and linear, branched, or cyclic. By the term,“polyamine” as used herein, it is meant any aliphatic or aromaticcompound containing two or more primary or secondary amine functionalgroups. The polyamine compound may have any suitable backbone chainstructure including saturated or unsaturated, and linear, branched, orcyclic. The term “polyamine” may be used interchangeably withamine-terminated component. By the term, “polyol” as used herein, it ismeant any aliphatic or aromatic compound containing two or more hydroxylfunctional groups. The term “polyol” may be used interchangeably withhydroxy-terminated component.

Thermoplastic polyurethanes have minimal cross-linking; any bonding inthe polymer network is primarily through hydrogen bonding or otherphysical mechanism. Because of their lower level of cross-linking,thermoplastic polyurethanes are relatively flexible. The cross-linkingbonds in thermoplastic polyurethanes can be reversibly broken byincreasing temperature such as during molding or extrusion. That is, thethermoplastic material softens when exposed to heat and returns to itsoriginal condition when cooled.

Thermoplastic polyurethanes are therefore particularly desirable as anouter cover layer material. Non-limiting examples of suitablethermoplastic polyurethanes include TPUs sold under the tradenames ofTexin® 250, Texin® 255, Texin® 260, Texin® 270, Texin®950U, Texin® 970U,Texin®1049, Texin®990DP7-1191, Texin® DP7-1202, Texin®990R, Texin®993,Texin®DP7-1049, Texin® 3203, Texin® 4203, Texin® 4206, Texin® 4210,Texin® 4215, and Texin® 3215, each commercially available from CovestroLLC, Pittsburgh Pa.; Estane® 50 DT3, Estane®58212, Estane®55DT3,Estane®58887, Estane®EZ14-23A, Estane®ETE 50DT3, each commerciallyavailable from Lubrizol Company of Cleveland, Ohio; andElastollan®WY1149, Elastollan®1154D53, Elastollan®1180A,Elastollan®1190A, Elastollan®1195A, Elastollan®1185AW,Elastollan®1175AW, each commercially available from BASF; Desmopan® 453,commercially available from Bayer of Pittsburgh, Pa., and the E-SeriesTPUs, such as D 60 E 4024 commercially available from HuntsmanPolyurethanes of Germany.

On the other hand, thermoset polyurethanes become irreversibly set whenthey are cured. The cross-linking bonds are irreversibly set and are notbroken when exposed to heat. Thus, thermoset polyurethanes, whichtypically have a high level of cross-linking, are relatively rigid.

Aromatic polyurethanes can be prepared in accordance with this inventionand these materials are preferably formed by reacting an aromaticdiisocyanate with a polyol. Suitable aromatic diisocyanates that may beused in accordance with this invention include, for example, toluene2,4-diisocyanate (TDI), toluene 2,6-diisocyanate (TDI), 4,4′-methylenediphenyl diisocyanate (MDI), 2,4′-methylene diphenyl diisocyanate (MDI),polymeric methylene diphenyl diisocyanate (PMDI), p-phenylenediisocyanate (PPDI), m-phenylene diisocyanate (PDI), naphthalene1,5-diisocynate (NDI), naphthalene 2,4-diisocyanate (NDI), p-xylenediisocyanate (XDI), and homopolymers and copolymers and blends thereof.The aromatic isocyanates are able to react with the hydroxyl or aminecompounds and form a durable and tough polymer having a high meltingpoint. The resulting polyurethane generally has good mechanical strengthand cut/shear-resistance.

Aliphatic polyurethanes also can be prepared in accordance with thisinvention and these materials are preferably formed by reacting analiphatic diisocyanate with a polyol. Suitable aliphatic diisocyanatesthat may be used in accordance with this invention include, for example,isophorone diisocyanate (IPDI), 1,6-hexamethylene diisocyanate (HDI),4,4′-dicyclohexylmethane diisocyanate (“H₁₂ MDI”),meta-tetramethylxylyene diisocyanate (TMXDI), trans-cyclohexanediisocyanate (CHDI), and homopolymers and copolymers and blends thereof.Particularly suitable multi-functional isocyanates include trimers ofHDI or H₁₂ MDI, oligomers, or other derivatives thereof. The resultingpolyurethane generally has good light and thermal stability.

Any polyol available to one of ordinary skill in the art is suitable foruse according to the invention. Exemplary polyols include, but are notlimited to, polyether polyols, hydroxy-terminated polybutadiene(including partially/fully hydrogenated derivatives), polyester polyols,polycaprolactone polyols, and polycarbonate polyols. In one preferredembodiment, the polyol includes polyether polyol. Examples include, butare not limited to, polytetramethylene ether glycol (PTMEG) which isparticularly preferred, polyethylene propylene glycol, polyoxypropyleneglycol, and mixtures thereof. The hydrocarbon chain can have saturatedor unsaturated bonds and substituted or unsubstituted aromatic andcyclic groups.

In another embodiment, polyester polyols are included in thepolyurethane material. Suitable polyester polyols include, but are notlimited to, polyethylene adipate glycol; polybutylene adipate glycol;polyethylene propylene adipate glycol; o-phthalate-1,6-hexanediol;poly(hexamethylene adipate) glycol; and mixtures thereof. Thehydrocarbon chain can have saturated or unsaturated bonds, orsubstituted or unsubstituted aromatic and cyclic groups. In stillanother embodiment, polycaprolactone polyols are included in thematerials of the invention. Suitable polycaprolactone polyols include,but are not limited to: 1,6-hexanediol-initiated polycaprolactone,diethylene glycol initiated polycaprolactone, trimethylol propaneinitiated polycaprolactone, neopentyl glycol initiated polycaprolactone,1,4-butanediol-initiated polycaprolactone, and mixtures thereof. Thehydrocarbon chain can have saturated or unsaturated bonds, orsubstituted or unsubstituted aromatic and cyclic groups. In yet anotherembodiment, polycarbonate polyols are included in the polyurethanematerial of the invention. Suitable polycarbonates include, but are notlimited to, polyphthalate carbonate and poly(hexamethylene carbonate)glycol. The hydrocarbon chain can have saturated or unsaturated bonds,or substituted or unsubstituted aromatic and cyclic groups. In oneembodiment, the molecular weight of the polyol is from about 200 toabout 4000.

There are two basic techniques that can be used to make thepolyurethanes: a) one-shot technique, and b) prepolymer technique. Inthe one-shot technique, the diisocyanate, polyol, andhydroxyl-terminated chain-extender (curing agent) are reacted in onestep. On the other hand, the prepolymer technique involves a firstreaction between the diisocyanate and polyol compounds to produce apolyurethane prepolymer, and a subsequent reaction between theprepolymer and hydroxyl-terminated chain-extender. As a result of thereaction between the isocyanate and polyol compounds, there will be someunreacted NCO groups in the polyurethane prepolymer. The prepolymershould have less than 14% unreacted NCO groups. Preferably, theprepolymer has no greater than 8.5% unreacted NCO groups, morepreferably from 2.5% to 8%, and most preferably from 5.0% to 8.0%unreacted NCO groups. As the weight percent of unreacted isocyanategroups increases, the hardness of the composition also generallyincreases. Either the one-shot or prepolymer method may be employed toproduce the polyurethane compositions of the invention. In oneembodiment, the one-shot method is used, wherein the isocyanate compoundis added to a reaction vessel and then a curative mixture comprising thepolyol and curing agent is added to the reaction vessel. The componentsare mixed together so that the molar ratio of isocyanate groups tohydroxyl groups is preferably in the range of about 1.00:1.00 to about1.10:1.00. In a second embodiment, the prepolymer method is used. Ingeneral, the prepolymer technique is preferred because it providesbetter control of the chemical reaction. The prepolymer method providesa more homogeneous mixture resulting in a more consistent polymercomposition. The one-shot method results in a mixture that isinhomogeneous (more random) and affords the manufacturer less controlover the molecular structure of the resultant composition.

The polyurethane compositions can be formed by chain-extending thepolyurethane prepolymer with a single chain-extender or blend ofchain-extenders as described further below. As discussed above, thepolyurethane prepolymer can be chain-extended by reacting it with asingle chain-extender or blend of chain-extenders. In general, theprepolymer can be reacted with hydroxyl-terminated curing agents,amine-terminated curing agents, and mixtures thereof. The curing agentsextend the chain length of the prepolymer and build-up its molecularweight. In general, thermoplastic polyurethane compositions aretypically formed by reacting the isocyanate blend and polyols at a 1:1stoichiometric ratio. Thermoset compositions, on the other hand, arecross-linked polymers and are typically produced from the reaction ofthe isocyanate blend and polyols at normally a 1.05:1 stoichiometricratio

A catalyst may be employed to promote the reaction between theisocyanate and polyol compounds for producing the prepolymer or betweenprepolymer and chain-extender during the chain-extending step.Preferably, the catalyst is added to the reactants before producing theprepolymer. Suitable catalysts include, but are not limited to, bismuthcatalyst; zinc octoate; stannous octoate; tin catalysts such asbis-butyltin dilaurate, bis-butyltin diacetate, stannous octoate; tin(II) chloride, tin (IV) chloride, bis-butyltin dimethoxide,dimethyl-bis[1-oxonedecyl)oxy]stannane, di-n-octyltin bis-isooctylmercaptoacetate; amine catalysts such as triethylenediamine,triethylamine, and tributylamine; organic acids such as oleic acid andacetic acid; delayed catalysts; and mixtures thereof. The catalyst ispreferably added in an amount sufficient to catalyze the reaction of thecomponents in the reactive mixture. In one embodiment, the catalyst ispresent in an amount from about 0.001 percent to about 1 percent, andpreferably 0.1 to 0.5 percent, by weight of the composition.

The hydroxyl chain-extending (curing) agents are preferably selectedfrom the group consisting of ethylene glycol; diethylene glycol;polyethylene glycol; propylene glycol; 2-methyl-1,3-propanediol;2-methyl-1,4-butanediol; monoethanolamine; diethanolamine;triethanolamine; monoisopropanolamine; diisopropanolamine; dipropyleneglycol; polypropylene glycol; 1,2-butanediol; 1,3-butanediol;1,4-butanediol; 2,3-butanediol; 2,3-dimethyl-2,3-butanediol;trimethylolpropane; cyclohexyldimethylol; triisopropanolamine;N,N,N′,N′-tetra-(2-hydroxypropyl)-ethylene diamine; diethylene glycolbis-(aminopropyl) ether; 1,5-pentanediol; 1,6-hexanediol;1,3-bis-(2-hydroxyethoxy) cyclohexane; 1,4-cyclohexyldimethylol;1,3-bis-[2-(2-hydroxyethoxy) ethoxy]cyclohexane;2,2′-(1,4-phenylenedioxy)diethanol,1,3-bis-{2-[2-(2-hydroxyethoxy)ethoxy]ethoxy}cyclohexane;trimethylolpropane; polytetramethylene ether glycol (PTMEG), preferablyhaving a molecular weight from about 250 to about 3900; and mixturesthereof.

Suitable amine chain-extending (curing) agents that can be used inchain-extending the polyurethane prepolymer include, but are not limitedto, unsaturated diamines such as 4,4′-diamino-diphenylmethane (i.e.,4,4′-methylene-dianiline or “MDA”), m-phenylenediamine,p-phenylenediamine, 1,2- or 1,4-bis(sec-butylamino)benzene,3,5-diethyl-(2,4- or 2,6-) toluenediamine or “DETDA”,3,5-dimethylthio-(2,4- or 2,6-)toluenediamine, 3,5-diethylthio-(2,4- or2,6-)toluenediamine, 3,3′-dimethyl-4,4′-diamino-diphenylmethane,3,3′-diethyl-5,5′-dimethyl4,4′-diamino-diphenylmethane (i.e.,4,4′-methylene-bis(2-ethyl-6-methyl-benezeneamine)),3,3′-dichloro-4,4′-diamino-diphenylmethane (i.e.,4,4′-methylene-bis(2-chloroaniline) or “MOCA”),3,3′,5,5′-tetraethyl-4,4′-diamino-diphenylmethane (i.e.,4,4′-methylene-bis(2,6-diethylaniline),2,2′-dichloro-3,3′,5,5′-tetraethyl-4,4′-diamino-diphenylmethane (i.e.,4,4′-methylene-bis(3-chloro-2,6-diethyleneaniline) or “MCDEA”),3,3′-diethyl-5,5′-dichloro-4,4′-diamino-diphenylmethane, or “MDEA”),3,3′-dichloro-2,2′,6,6′-tetraethyl-4,4′-diamino-diphenylmethane,3,3′-dichloro-4,4′-diamino-diphenylmethane,4,4′-methylene-bis(2,3-dichloroaniline) (i.e.,2,2′,3,3′-tetrachloro-4,4′-diamino-diphenylmethane or “MDCA”); andmixtures thereof. One particularly suitable amine-terminatedchain-extending agent is Ethacure 300™ (dimethylthiotoluenediamine or amixture of 2,6-diamino-3,5-dimethylthiotoluene and2,4-diamino-3,5-dimethylthiotoluene.) The amine curing agents used aschain extenders normally have a cyclic structure and a low molecularweight (250 or less).

When the polyurethane prepolymer is reacted with hydroxyl-terminatedcuring agents during the chain-extending step, as described above, theresulting polyurethane composition contains urethane linkages. On theother hand, when the polyurethane prepolymer is reacted withamine-terminated curing agents during the chain-extending step, anyexcess isocyanate groups in the prepolymer will react with the aminegroups in the curing agent. The resulting polyurethane compositioncontains urethane and urea linkages and may be referred to as apolyurethane/urea hybrid. The concentration of urethane and urealinkages in the hybrid composition may vary. In general, the hybridcomposition may contain a mixture of about 10 to 90% urethane and about90 to 10% urea linkages.

More particularly, when the polyurethane prepolymer is reacted withhydroxyl-terminated curing agents during the chain-extending step, asdescribed above, the resulting composition is essentially a purepolyurethane composition containing urethane linkages having thefollowing general structure:

where x is the chain length, i.e., about 1 or greater, and R and R₁ arestraight chain or branched hydrocarbon chain having about 1 to about 20carbons.

However, when the polyurethane prepolymer is reacted with anamine-terminated curing agent during the chain-extending step, anyexcess isocyanate groups in the prepolymer will react with the aminegroups in the curing agent and create urea linkages having the followinggeneral structure:

where x is the chain length, i.e., about 1 or greater, and R and R₁ arestraight chain or branched hydrocarbon chain having about 1 to about 20carbons.

The polyurethane compositions used to form the cover layer may containother polymer materials including, for example: aliphatic or aromaticpolyurethanes, aliphatic or aromatic polyureas, aliphatic or aromaticpolyurethane/urea hybrids, olefin-based copolymer ionomer compositions,polyethylene, including, for example, low density polyethylene, linearlow density polyethylene, and high density polyethylene; polypropylene;rubber-toughened olefin polymers; acid copolymers, for example,poly(meth)acrylic acid, which do not become part of an ionomericcopolymer; plastomers; flexomers; styrene/butadiene/styrene blockcopolymers; styrene/ethylene-butylene/styrene block copolymers;dynamically vulcanized elastomers; copolymers of ethylene and vinylacetates; copolymers of ethylene and methyl acrylates; polyvinylchloride resins; polyamides, poly(amide-ester) elastomers, and graftcopolymers of ionomer and polyamide including, for example, Pebax®thermoplastic polyether block amides, available from Arkema Inc;cross-linked trans-polyisoprene and blends thereof; polyester-basedthermoplastic elastomers, such as Hytrel®, available from DuPont;polyurethane-based thermoplastic elastomers, such as Elastollan®,available from BASF; polycarbonate/polyester blends such as Xylex®,available from SABIC Innovative Plastics; maleic anhydride-graftedpolymers such as Fusabond®, available from DuPont; and mixtures of theforegoing materials.

In addition, the polyurethane compositions may contain fillers,additives, and other ingredients that do not detract from the propertiesof the final composition. These additional materials include, but arenot limited to, catalysts, wetting agents, coloring agents, opticalbrighteners, cross-linking agents, whitening agents such as titaniumdioxide and zinc oxide, ultraviolet (UV) light absorbers, hindered aminelight stabilizers, defoaming agents, processing aids, surfactants, andother conventional additives. Other suitable additives includeantioxidants, stabilizers, softening agents, plasticizers, includinginternal and external plasticizers, impact modifiers, foaming agents,density-adjusting fillers, reinforcing materials, compatibilizers, andthe like. Some examples of useful fillers include zinc oxide, zincsulfate, barium carbonate, barium sulfate, calcium oxide, calciumcarbonate, clay, tungsten, tungsten carbide, silica, and mixturesthereof. Rubber regrind (recycled core material) and polymeric, ceramic,metal, and glass microspheres also may be used. Generally, the additiveswill be present in the composition in an amount between about 1 andabout 70 weight percent based on total weight of the compositiondepending upon the desired properties.

Thermoplastic polyurea compositions are typically formed by reacting theisocyanate blend and polyamines at a 1:1 stoichiometric ratio. Thepolyurea prepolymer can be chain-extended by reacting it with a singlecuring agent or blend of curing agents. In general, the prepolymer canbe reacted with hydroxyl-terminated curing agents, amine-terminatedcuring agents, or mixtures thereof. The curing agents extend the chainlength of the prepolymer and build-up its molecular weight. Normally,the prepolymer and curing agent are mixed so the isocyanate groups andhydroxyl or amine groups are mixed at a 1.05:1.00 stoichiometric ratio.

A catalyst may be employed to promote the reaction between theisocyanate and polyamine compounds for producing the prepolymer orbetween prepolymer and curing agent during the chain-extending step.Preferably, the catalyst is added to the reactants before producing theprepolymer. Suitable catalysts include, but are not limited to, thoseidentified above in connection with promoting the reaction between theisocyanate and polyol compounds for producing the prepolymer or betweenprepolymer and chain-extender during the chain-extending step.

The hydroxyl chain-extending (curing) agents are preferably selectedfrom the same group identified above in connection with polyurethanecompositions.

Suitable amine chain-extending (curing) agents that can be used inchain-extending the polyurea prepolymer of this invention include, butare not limited to those identified above in connection withchain-extending the polyurethane prepolymer, as well as4,4′-bis(sec-butylamino)-diphenylmethane,N,N′-dialkylamino-diphenylmethane,trimethyleneglycol-di(p-aminobenzoate),polyethyleneglycol-di(p-aminobenzoate),polytetramethyleneglycol-di(p-aminobenzoate); saturated diamines such asethylene diamine, 1,3-propylene diamine, 2-methyl-pentamethylenediamine, hexamethylene diamine, 2,2,4- and 2,4,4-trimethyl-1,6-hexanediamine, imino-bis(propylamine), imido-bis(propylamine),methylimino-bis(propylamine) (i.e.,N-(3-aminopropyl)-N-methyl-1,3-propanediamine),1,4-bis(3-aminopropoxy)butane (i.e.,3,3′-[1,4-butanediylbis-(oxy)bis]-1-propanamine),diethyleneglycol-bis(propylamine) (i.e.,diethyleneglycol-di(aminopropyl)ether),4,7,10-trioxatridecane-1,13-diamine, 1-methyl-2,6-diamino-cyclohexane,1,4-diamino-cyclohexane, poly(oxyethylene-oxypropylene) diamines, 1,3-or 1,4-bis(methylamino)-cyclohexane, isophorone diamine, 1,2- or1,4-bis(sec-butylamino)-cyclohexane, N,N′-diisopropyl-isophoronediamine, 4,4′-diamino-dicyclohexylmethane,3,3′-dimethyl-4,4′-diamino-dicyclohexylmethane,3,3′-dichloro-4,4′-diamino-dicyclohexylmethane,N,N′-dialkylamino-dicyclohexylmethane, polyoxyethylene diamines,3,3′-diethyl-5,5′-dimethyl-4,4′-diamino-dicyclohexylmethane,polyoxypropylene diamines,3,3′-diethyl-5,5′-dichloro-4,4′-diamino-dicyclohexylmethane,polytetramethylene ether diamines,3,3′,5,5′-tetraethyl-4,4′-diamino-dicyclohexylmethane (i.e.,4,4′-methylene-bis(2,6-diethylaminocyclohexane)),3,3′-dichloro-4,4′-diamino-dicyclohexylmethane,2,2′-dichloro-3,3′,5,5′-tetraethyl-4,4′-diamino-dicyclohexylmethane,(ethylene oxide)-capped polyoxypropylene ether diamines,2,2′,3,3′-tetrachloro-4,4′-diamino-dicyclohexylmethane,4,4′-bis(sec-butylamino)-dicyclohexylmethane; triamines such asdiethylene triamine, dipropylene triamine, (propylene oxide)-basedtriamines (i.e., polyoxypropylene triamines),N-(2-aminoethyl)-1,3-propylenediamine (i.e., N₃-amine), glycerin-basedtriamines, (all saturated); tetramines such asN,N′-bis(3-aminopropyl)ethylene diamine (i.e., N₄-amine) (bothsaturated), triethylene tetramine; and other polyamines such astetraethylene pentamine (also saturated).

When the polyurea prepolymer is reacted with amine-terminated curingagents during the chain-extending step, as described above, theresulting composition is essentially a pure polyurea composition. On theother hand, when the polyurea prepolymer is reacted with ahydroxyl-terminated curing agent during the chain-extending step, anyexcess isocyanate groups in the prepolymer will react with the hydroxylgroups in the curing agent and create urethane linkages to form apolyurea-urethane hybrid. Herein, the terms urea and polyurea are usedinterchangeably.

This chain-extending step, which occurs when the polyurea prepolymer isreacted with hydroxyl curing agents, amine curing agents, or mixturesthereof, builds-up the molecular weight and extends the chain length ofthe prepolymer. When the polyurea prepolymer is reacted with aminecuring agents, a polyurea composition having urea linkages is produced.When the polyurea prepolymer is reacted with hydroxyl curing agents, apolyurea/urethane hybrid composition containing both urea and urethanelinkages is produced. The polyurea/urethane hybrid composition isdistinct from the pure polyurea composition. The concentration of ureaand urethane linkages in the hybrid composition may vary. In general,the hybrid composition may contain a mixture of about 10 to 90% urea andabout 90 to 10% urethane linkages. The resulting polyurea orpolyurea/urethane hybrid composition has elastomeric properties based onphase separation of the soft and hard segments. The soft segments, whichare formed from the polyamine reactants, are generally flexible andmobile, while the hard segments, which are formed from the isocyanatesand chain extenders, are generally stiff and immobile.

Golf balls disclosed herein may have any known overall diameter andinclude any known number of different layers and layer thicknesses as isrequired to target desired playing characteristics and performanceproperties such as hardness, compression, modulus, tensile strength andultimate elongation, CoR (coefficient of restitution), spin, and/orinitial velocity to name a few.

For example, the core may have an overall diameter ranging from about0.09 inches to about 1.65 inches, or up to about 1.70 inches, or greaterthan 1.70 inches. The core may in some embodiments have a diameterranging from about 1.5 inches to about 1.62 inches. In anotherembodiment, the diameter of the core is about 1.3 inches to about 1.6inches, preferably from about 1.39 inches to about 1.6 inches, and morepreferably from about 1.5 inches to about 1.6 inches. In yet anotherembodiment, the core has a diameter of about 1.55 inches to about 1.65inches, preferably about 1.55 inches to about 1.60 inches.

In some embodiments, the core may have an overall diameter within arange having a lower limit of 0.500 or 0.700 or 0.750 or 0.800 or 0.850or 0.900 or 0.950 or 1.000 or 1.100 or 1.150 or 1.200 or 1.250 or 1.300or 1.350 or 1.400 or 1.450 or 1.500 or 1.600 or 1.610 inches and anupper limit of 1.620 or 1.630 or 1.640 inches. In a particularembodiment, the core has an overall diameter within a range having alower limit of 0.500 or 0.700 or 0.750 or 0.800 or 0.850 or 0.900 or0.950 or 1.000 or 1.100 or 1.150 or 1.200 inches and an upper limit of1.250 or 1.300 or 1.350 or 1.400 or 1.450 or 1.500 or 1.600 or 1.610 or1.620 or 1.630 or 1.640 inches. In another particular embodiment, thecore has an overall diameter within a range having a lower limit of0.500 or 0.700 or 0.750 inches and an upper limit of 0.800 or 0.850 or0.900 or 0.950 or 1.000 or 1.100 or 1.150 or 1.200 or 1.250 or 1.300 or1.350 or 1.400 or 1.450 or 1.500 or 1.600 or 1.610 or 1.620 or 1.630 or1.640 inches. In another particular embodiment, the core has an overalldiameter of 1.500 inches or 1.510 inches or 1.530 inches or 1.550 inchesor 1.570 inches or 1.580 inches or 1.590 inches or 1.600 inches or 1.610inches or 1.620 inches.

In some embodiments, the core can have an overall diameter of 0.500inches or greater, or 0.700 inches or greater, or 1.00 inches orgreater, or 1.250 inches or greater, or 1.350 inches or greater, or1.390 inches or greater, or 1.450 inches or greater, or an overalldiameter within a range having a lower limit of 0.250 or 0.500 or 0.750or 1.000 or 1.250 or 1.350 or 1.390 or 1.400 or 1.440 inches and anupper limit of 1.460 or 1.490 or 1.500 or 1.550 or 1.580 or 1.600inches, or an overall diameter within a range having a lower limit of0.250 or 0.300 or 0.350 or 0.400 or 0.500 or 0.550 or 0.600 or 0.650 or0.700 inches and an upper limit of 0.750 or 0.800 or 0.900 or 0.950 or1.000 or 1.100 or 1.150 or 1.200 or 1.250 or 1.300 or 1.350 or 1.400inches.

The core generally has an overall compression in the range of from about40 to about 110, although embodiments are envisioned wherein thecompression of the core is as low as 5.

In other embodiments, the overall CoR of cores of the present inventionat 125 ft/s is at least 0.750, or at least 0.775 or at least 0.780, orat least 0.785, or at least 0.790, or at least 0.795, or at least 0.810.

The range of thicknesses for an intermediate layer of a golf ball islarge because of the vast possibilities when using an intermediatelayer, i.e., as an inner cover layer, moisture/vapor barrier layer, filmlayer, coating layer, etc. Thus, when used in a golf ball disclosedherein, the intermediate layer may have any known thickness such as athickness of about 0.3 inches or less, or from about 0.002 inches toabout 0.1 inches, or of about 0.01 inches or greater.

For example, the intermediate layer and/or inner cover layer may have athickness ranging from about 0.010 inches to about 0.06 inches. Inanother embodiment, the intermediate layer thickness is about 0.05inches or less, or about 0.01 inches to about 0.045 inches for example.

Moisture/vapor barrier layers and/or film layers may have a thickness,for example, of from 0.0003 inches to 0.010 inches.

If the golf ball includes an intermediate layer or inner cover layer,the hardness (material) thereof may be for example about 50 Shore D orgreater, more preferably about 55 Shore D or greater, and mostpreferably about 60 Shore D or greater. In one embodiment, the innercover has a Shore D hardness of about 62 to about 90 Shore D. In oneexample, the inner cover has a hardness of about 68 Shore D or greater.In addition, the thickness of the inner cover layer may for example beabout 0.015 inches to about 0.100 inches, or about 0.020 inches to about0.080 inches, or about 0.030 inches to about 0.050 inches, but onceagain, may be changed to target playing characteristics.

The cover typically has a thickness to provide sufficient strength, goodperformance characteristics, and durability. In one embodiment, thecover thickness may for example be from about 0.02 inches to about 0.12inches, or about 0.1 inches or less. For example, the cover may be partof a two-piece golf ball and have a thickness ranging from about 0.03inches to about 0.09 inches. In another embodiment, the cover thicknessmay be about 0.05 inches or less, or from about 0.02 inches to about0.05 inches, or from about 0.02 inches and about 0.045 inches.

The cover may be a single-, dual-, or multi-layer cover and have anoverall thickness for example within a range having a lower limit of0.010 or 0.020 or 0.025 or 0.030 or 0.040 or 0.045 inches and an upperlimit of 0.050 or 0.060 or 0.070 or 0.075 or 0.080 or 0.090 or 0.100 or0.150 or 0.200 or 0.300 or 0.500 inches. In a particular embodiment, thecover may be a single layer having a thickness of from 0.010 or 0.020 or0.025 inches to 0.035 or 0.040 or 0.050 inches. In another particularembodiment, the cover may consist of an inner cover layer having athickness of from 0.010 or 0.020 or 0.025 inches to 0.035 or 0.050inches and an outer cover layer having a thickness of from 0.010 or0.020 or 0.025 inches to 0.035 or 0.040 inches.

The outer cover preferably has a thickness within a range having a lowerlimit of about 0.004 or 0.010 or 0.020 or 0.030 or 0.040 inches and anupper limit of about 0.050 or 0.055 or 0.065 or 0.070 or 0.080 inches.Preferably, the thickness of the outer cover is about 0.020 inches orless. The outer cover preferably has a surface hardness of 75 Shore D orless, 65 Shore D or less, or 55 Shore D or less, or 50 Shore D or less,or 50 Shore D or less, or 45 Shore D or less. Preferably, the outercover has hardness in the range of about 20 to about 70 Shore D. In oneexample, the outer cover has hardness in the range of about 25 to about65 Shore D.

In one embodiment, the cover may be a single layer having a surfacehardness for example of 60 Shore D or greater, or 65 Shore D or greater.In a particular aspect of this embodiment, the cover is formed from acomposition having a material hardness of 60 Shore D or greater, or 65Shore D or greater.

In another particular embodiment, the cover may be a single layer havinga thickness of from 0.010 or 0.020 inches to 0.035 or 0.050 inches andformed from a composition having a material hardness of from 60 or 62 or65 Shore D to 65 or 70 or 72 Shore D.

In yet another particular embodiment, the cover is a single layer havinga thickness of from 0.010 or 0.025 inches to 0.035 or 0.040 inches andformed from a composition having a material hardness of 62 Shore D orless, or less than 62 Shore D, or 60 Shore D or less, or less than 60Shore D, or 55 Shore D or less, or less than 55 Shore D.

In still another particular embodiment, the cover is a single layerhaving a thickness of from 0.010 or 0.025 inches to 0.035 or 0.040inches and formed from a composition having a material hardness of 62Shore D or less, or less than 62 Shore D, or 60 Shore D or less, or lessthan 60 Shore D, or 55 Shore D or less, or less than 55 Shore D.

In an alternative embodiment, the cover may comprise an inner coverlayer and an outer cover layer. The inner cover layer composition mayhave a material hardness of from 60 or 62 or 65 Shore D to 65 or 70 or72 Shore D. The inner cover layer may have a thickness within a rangehaving a lower limit of 0.010 or 0.020 or 0.030 inches and an upperlimit of 0.035 or 0.040 or 0.050 inches. The outer cover layercomposition may have a material hardness of 62 Shore D or less, or lessthan 62 Shore D, or 60 Shore D or less, or less than 60 Shore D, or 55Shore D or less, or less than 55 Shore D. The outer cover layer may havea thickness within a range having a lower limit of 0.010 or 0.020 or0.025 inches and an upper limit of 0.035 or 0.040 or 0.050 inches.

In yet another embodiment, the cover is a dual- or multi-layer coverincluding an inner or intermediate cover layer and an outer cover layer.The inner cover layer may have a surface hardness of 70 Shore D or less,or 65 Shore D or less, or less than 65 Shore D, or a Shore D hardness offrom 50 to 65, or a Shore D hardness of from 57 to 60, or a Shore Dhardness of 58, and a thickness within a range having a lower limit of0.010 or 0.020 or 0.030 inches and an upper limit of 0.045 or 0.080 or0.120 inches. The outer cover layer may have a material hardness of 65Shore D or less, or 55 Shore D or less, or 45 Shore D or less, or 40Shore D or less, or from 25 Shore D to 40 Shore D, or from 30 Shore D to40 Shore D. The outer cover layer may have a surface hardness within arange having a lower limit of 20 or 30 or 35 or 40 Shore D and an upperlimit of 52 or 58 or 60 or 65 or 70 or 72 or 75 Shore D. The outer coverlayer may have a thickness within a range having a lower limit of 0.010or 0.015 or 0.025 inches and an upper limit of 0.035 or 0.040 or 0.045or 0.050 or 0.055 or 0.075 or 0.080 or 0.115 inches.

All this being said, embodiments are also envisioned wherein one or moreof the cover layers is formed from a material typically incorporated ina core or intermediate layer.

It is envisioned that layers the golf ball may be incorporated via anyof casting, compression molding, injection molding, or thermoforming asdesired.

Those layers of golf balls of the invention comprising conventionalthermoplastic or thermoset materials may be formed using a variety ofconventional application techniques such as compression molding, flipmolding, injection molding, retractable pin injection molding, reactioninjection molding (RIM), liquid injection molding (LIM), casting, vacuumforming, powder coating, flow coating, spin coating, dipping, spraying,and the like. Conventionally, compression molding and injection moldingare applied to thermoplastic materials, whereas

RIM, liquid injection molding, and casting are employed on thermosetmaterials. These and other manufacture methods are disclosed in U.S.Pat. Nos. 6,207,784 and 5,484,870, the disclosures of which areincorporated herein by reference in their entireties.

A method of injection molding using a split vent pin can be found inco-pending U.S. Pat. No. 6,877,974, filed Dec. 22, 2000, entitled “SplitVent Pin for Injection Molding.” Examples of retractable pin injectionmolding may be found in U.S. Pat. Nos. 6,129,881; 6,235,230; and6,379,138. These molding references are incorporated in their entiretyby reference herein. In addition, a chilled chamber, i.e., a coolingjacket, such as the one disclosed in U.S. Pat. No. 6,936,205, filed Nov.22, 2000, entitled “Method of Making Golf Balls” may be used to cool thecompositions of the invention when casting, which also allows for ahigher loading of catalyst into the system.

Golf balls of the invention may include at least one compression moldedlayer. Conventionally, compression molding and injection molding areapplied to thermoplastic materials, whereas RIM, liquid injectionmolding, and casting are employed on thermoset materials. These andother manufacture methods are disclosed in U.S. Pat. Nos. 5,484,870;5,935,500; 6,207,784; 6,436,327; 7,648,667; 6,562,912; 6,913,726;7,204,946; 8,980,151; 9,211,662; U.S. Publs. Nos. 2003/0067088; and2013/0072323; the disclosures of each of which are incorporated hereinby reference in their entirety.

Castable reactive liquid polyurethanes and polyurea materials may beapplied over the inner ball using a variety of application techniquessuch as casting, injection molding spraying, compression molding,dipping, spin coating, or flow coating methods that are well known inthe art. In one embodiment, the castable reactive polyurethanes andpolyurea material is formed over the core using a combination of castingand compression molding. Conventionally, compression molding andinjection molding are applied to thermoplastic cover materials, whereasRIM, liquid injection molding, and casting are employed on thermosetcover materials.

U.S. Pat. No. 5,733,428, the entire disclosure of which is herebyincorporated by reference, discloses a method for forming a polyurethanecover on a golf ball core. Because this method relates to the use ofboth casting thermosetting and thermoplastic material as the golf ballcover, wherein the cover is formed around the core by mixing andintroducing the material in mold halves, the polyurea compositions mayalso be used employing the same casting process.

For example, once a polyurea composition is mixed, an exothermicreaction commences and continues until the material is solidified aroundthe core. It is important that the viscosity be measured over time, sothat the subsequent steps of filling each mold half, introducing thecore into one half and closing the mold can be properly timed foraccomplishing centering of the core cover halves fusion and achievingoverall uniformity. A suitable viscosity range of the curing urea mixfor introducing cores into the mold halves is determined to beapproximately between about 2,000 cP and about 30,000 cP, or within arange of about 8,000 cP to about 15,000 cP.

To start the cover formation, mixing of the prepolymer and curative isaccomplished in a motorized mixer inside a mixing head by feedingthrough lines metered amounts of curative and prepolymer. Top preheatedmold halves are filled and placed in fixture units using centering pinsmoving into apertures in each mold. At a later time, the cavity of abottom mold half, or the cavities of a series of bottom mold halves, isfilled with similar mixture amounts as used for the top mold halves.After the reacting materials have resided in top mold halves for about40 to about 100 seconds, preferably for about 70 to about 80 seconds, acore is lowered at a controlled speed into the gelling reacting mixture.

A ball cup holds the shell through reduced pressure (or partial vacuum).Upon location of the core in the halves of the mold after gelling forabout 4 to about 12 seconds, the vacuum is released allowing the core tobe released. In one embodiment, the vacuum is released allowing the coreto be released after about 5 seconds to 10 seconds. The mold halves,with core and solidified cover half thereon, are removed from thecentering fixture unit, inverted and mated with second mold halveswhich, at an appropriate time earlier, have had a selected quantity ofreacting polyurea prepolymer and curing agent introduced therein tocommence gelling.

Similarly, U.S. Pat. Nos. 5,006,297 and 5,334,673 both also disclosesuitable molding techniques that may be utilized to apply the castablereactive liquids employed in the present invention.

However, golf balls of the invention may be made by any known techniqueto those skilled in the art.

Examples of yet other materials which may be suitable for incorporatingand coordinating in order to target and achieve desired playingcharacteristics or feel include plasticized thermoplastics,polyalkenamer compositions, polyester-based thermoplastic elastomerscontaining plasticizers, transparent or plasticized polyamides, thiolenecompositions, poly-amide and anhydride-modified polyolefins, organicacid-modified polymers, and the like.

The solid cores for the golf balls of this invention may be made usingany suitable conventional technique such as, for example, compression orinjection-molding, Typically, the cores are formed by compressionmolding a slug of uncured or lightly cured rubber material into aspherical structure. Prior to forming the cover layer, the corestructure may be surface-treated to increase the adhesion between itsouter surface and adjacent layer. Such surface-treatment may includemechanically or chemically-abrading the outer surface of the core. Forexample, the core may be subjected to corona-discharge,plasma-treatment, silane-dipping, or other treatment methods known tothose in the art. The cover layers are formed over the core or ballsub-assembly (the core structure and any intermediate layers disposedabout the core) using any suitable method as described further below.Prior to forming the cover layers, the ball sub-assembly may besurface-treated to increase the adhesion between its outer surface andthe overlying cover material using the above-described techniques.

Conventional compression and injection-molding and other methods can beused to form cover layers over the core or ball sub-assembly. Ingeneral, compression molding normally involves first making half(hemispherical) shells by injection-molding the composition in aninjection mold or creating preforms from extrudate. This producessemi-cured, semi-rigid half-shells (or cups). Then, the half-shells arepositioned in a compression mold around the core or ball sub-assembly.Heat and pressure are applied and the half-shells fuse together to forma cover layer over the core or sub-assembly. Compression molding alsocan be used to cure the cover composition after injection-molding. Forexample, a thermally-curable composition can be injection-molded arounda core in an unheated mold. After the composition is partially hardened,the ball is removed and placed in a compression mold. Heat and pressureare applied to the ball and this causes thermal-curing of the outercover layer.

Retractable pin injection-molding (RPIM) methods generally involve usingupper and lower mold cavities that are mated together. The upper andlower mold cavities form a spherical interior cavity when they arejoined together. The mold cavities used to form the outer cover layerhave interior dimple cavity details. The cover material conforms to theinterior geometry of the mold cavities to form a dimple pattern on thesurface of the ball. The injection-mold includes retractable supportpins positioned throughout the mold cavities. The retractable supportpins move in and out of the cavity. The support pins help maintain theposition of the core or ball sub-assembly while the molten compositionflows through the mold gates. The molten composition flows into thecavity between the core and mold cavities to surround the core and formthe cover layer. Other methods can be used to make the cover including,for example, reaction injection-molding (RIM), liquid injection-molding,casting, spraying, powder-coating, vacuum-forming, flow-coating,dipping, spin-coating, and the like.

As discussed above, an inner cover layer or intermediate layer,preferably formed from an ethylene acid copolymer ionomer composition,can be formed between the core or ball sub-assembly and cover layer. Theintermediate layer comprising the ionomer composition may be formedusing a conventional technique such as, for example, compression orinjection-molding. For example, the ionomer composition may beinjection-molded or placed in a compression mold to produce half-shells.These shells are placed around the core in a compression mold, and theshells fuse together to form an intermediate layer. Alternatively, theionomer composition is injection-molded directly onto the core usingretractable pin injection-molding.

After the golf balls have been removed from the mold, they may besubjected to finishing steps such as flash-trimming, surface-treatment,marking, and one or more coating layer may be applied as desired viamethods such as spraying, dipping, brushing, or rolling. Then the golfball can go through a series of finishing steps.

The resulting balls of this invention have good impact durability andcut/shear-resistance. The United States Golf Association (“USGA”) hasset total weight limits for golf balls. Particularly, the USGA hasestablished a maximum weight of 45.93 g (1.62 ounces) for golf balls.There is no lower weight limit. In addition, the USGA requires that golfballs used in competition have a diameter of at least 1.68 inches. Thereis no upper limit so many golf balls have an overall diameter fallingwithin the range of about 1.68 to about 1.80 inches. The golf balldiameter is preferably about 1.68 to 1.74 inches, more preferably about1.68 to 1.70 inches. In accordance with the present invention, theweight, diameter, and thickness of the core and cover layers may beadjusted, as needed, so the ball meets USGA specifications of a maximumweight of 1.62 ounces and a minimum diameter of at least 1.68 inches.

Preferably, the golf ball has a Coefficient of Restitution (CoR) of atleast 0.750 and more preferably at least 0.800 (as measured per the testmethods below). The core of the golf ball generally has a compression inthe range of about 30 to about 130 and more preferably in the range ofabout 70 to about 110 (as measured per the test methods below.) Theseproperties allow players to generate greater ball velocity off the teeand achieve greater distance with their drives. At the same time, therelatively thin outer cover layer means that a player will have a morecomfortable and natural feeling when striking the ball with a club. Theball is more playable and its flight path can be controlled more easily.This control allows the player to make better approach shots near thegreen. Furthermore, the outer covers of this invention have good impactdurability and mechanical strength.

The following test methods may be used to obtain certain properties inconnection with golf balls of the invention and layers thereof.

Hardness. The center hardness of a core is obtained according to thefollowing procedure. The core is gently pressed into a hemisphericalholder having an internal diameter approximately slightly smaller thanthe diameter of the core, such that the core is held in place in thehemispherical of the holder while concurrently leaving the geometriccentral plane of the core exposed. The core is secured in the holder byfriction, such that it will not move during the cutting and grindingsteps, but the friction is not so excessive that distortion of thenatural shape of the core would result. The core is secured such thatthe parting line of the core is roughly parallel to the top of theholder. The diameter of the core is measured 90 degrees to thisorientation prior to securing. A measurement is also made from thebottom of the holder to the top of the core to provide a reference pointfor future calculations. A rough cut is made slightly above the exposedgeometric center of the core using a band saw or other appropriatecutting tool, making sure that the core does not move in the holderduring this step. The remainder of the core, still in the holder, issecured to the base plate of a surface grinding machine. The exposed‘rough’ surface is ground to a smooth, flat surface, revealing thegeometric center of the core, which can be verified by measuring theheight from the bottom of the holder to the exposed surface of the core,making sure that exactly half of the original height of the core, asmeasured above, has been removed to within 0.004 inches. Leaving thecore in the holder, the center of the core is found with a center squareand carefully marked and the hardness is measured at the center markaccording to ASTM D-2240. Additional hardness measurements at anydistance from the center of the core can then be made by drawing a lineradially outward from the center mark, and measuring the hardness at anygiven distance along the line, typically in 2 mm increments from thecenter. The hardness at a particular distance from the center should bemeasured along at least two, preferably four, radial arms located 180°apart, or 90° apart, respectively, and then averaged. All hardnessmeasurements performed on a plane passing through the geometric centerare performed while the core is still in the holder and without havingdisturbed its orientation, such that the test surface is constantlyparallel to the bottom of the holder, and thus also parallel to theproperly aligned foot of the durometer.

The outer surface hardness of a golf ball layer is measured on theactual outer surface of the layer and is obtained from the average of anumber of measurements taken from opposing hemispheres, taking care toavoid making measurements on the parting line of the core or on surfacedefects, such as holes or protrusions. Hardness measurements are madepursuant to ASTM D-2240 “Indentation Hardness of Rubber and Plastic byMeans of a Durometer.” Because of the curved surface, care must be takento ensure that the golf ball or golf ball sub-assembly is centered underthe durometer indenter before a surface hardness reading is obtained. Acalibrated, digital durometer, capable of reading to 0.1 hardness unitsis used for the hardness measurements. The digital durometer must beattached to, and its foot made parallel to, the base of an automaticstand. The weight on the durometer and attack rate conforms to ASTMD-2240.

In certain embodiments, a point or plurality of points measured alongthe “positive” or “negative” gradients may be above or below a line fitthrough the gradient and its outermost and innermost hardness values. Inan alternative preferred embodiment, the hardest point along aparticular steep “positive” or “negative” gradient may be higher thanthe value at the innermost of the inner core (the geometric center) orouter core layer (the inner surface)—as long as the outermost point(i.e., the outer surface of the inner core) is greater than (for“positive”) or lower than (for “negative”) the innermost point (i.e.,the geometric center of the inner core or the inner surface of the outercore layer), such that the “positive” and “negative” gradients remainintact.

As discussed above, the direction of the hardness gradient of a golfball layer is defined by the difference in hardness measurements takenat the outer and inner surfaces of a particular layer. The centerhardness of an inner core and hardness of the outer surface of an innercore in a single-core ball or outer core layer are readily determinedaccording to the test procedures provided above. The outer surface ofthe inner core layer (or other optional intermediate core layers) in adual-core ball are also readily determined according to the proceduresgiven herein for measuring the outer surface hardness of a golf balllayer, if the measurement is made prior to surrounding the layer with anadditional core layer. Once an additional core layer surrounds a layerof interest, the hardness of the inner and outer surfaces of any inneror intermediate layers can be difficult to determine. Therefore, forpurposes of the present invention, when the hardness of the inner orouter surface of a core layer is needed after the inner layer has beensurrounded with another core layer, the test procedure described abovefor measuring a point located 1 mm from an interface is used.

Also, it should be understood that there is a fundamental differencebetween “material hardness” and “hardness as measured directly on a golfball.” For purposes of the present invention, material hardness ismeasured according to ASTM D2240 and generally involves measuring thehardness of a flat “slab” or “button” formed of the material. Surfacehardness as measured directly on a golf ball (or other sphericalsurface) typically results in a different hardness value. The differencein “surface hardness” and “material hardness” values is due to severalfactors including, but not limited to, ball construction (that is, coretype, number of cores and/or cover layers, and the like); ball (orsphere) diameter; and the material composition of adjacent layers. Italso should be understood that the two measurement techniques are notlinearly related and, therefore, one hardness value cannot easily becorrelated to the other. Shore hardness (for example, Shore C or Shore Dor Shore A hardness) was measured according to the test method ASTMD-2240.

Thermoset and thermoplastic layers herein may be treated in such amanner as to create a positive or negative hardness gradient within andbetween golf ball layers. In golf ball layers of the present inventionwherein a thermosetting rubber is used, gradient-producing processesand/or gradient-producing rubber formulation may be employed.Gradient-producing processes and formulations are disclosed more fully,for example, in U.S. patent application Ser. Nos. 12/048,665, filed onMar. 14, 2008; 11/829,461, filed on Jul. 27, 2007; 11/772,903, filedJul. 3, 2007; 11/832,163, filed Aug. 1, 2007; 11/832,197, filed on Aug.1, 2007; the entire disclosure of each of these references is herebyincorporated herein by reference.

Hardness gradient of an outer core layer may be defined by hardnessmeasurements made at the surface of the outer core layer and at pointsradially inward towards the geometric center of the inner core,typically at 2-mm increments. In turn, a hardness gradient of the innercore is defined by hardness measurements made at the surface of theinner core and likewise at points radially inward toward the geometriccenter.

As used herein, the terms “negative” and “positive” hardness gradientsrefer to the result of subtracting the hardness value at the innermostportion of the component being measured (e.g., the geometric center of asolid inner core in a dual core construction; and the inner surface ofan outer core layer; etc.) from the hardness value at the outer surfaceof the component being measured (e.g., the outer surface of the solidinner core; and the outer surface of the outer core layer, etc.). Forexample, if the outer surface of the solid inner core has a lowerhardness value than does the geometric center (i.e., the surface issofter than the geometric center), the hardness gradient will be deemeda “negative” gradient (a smaller number−a larger number=a negativenumber). And if the outer surface of the outer core layer has a has agreater hardness value than the inner surface of the outer core layer,this is a “hard-to-soft” or “positive” hardness gradient as measuredradially inward from the outer core outer surface. It is also possibleto create a “zero” hardness gradient, which is generally defined as nogradient as well as a gradient of less than 1 Shore C hardness point ineither the negative or positive hardness gradient direction. Methods formeasuring the hardness of the inner core and surrounding layers anddetermining the hardness gradients are discussed in further detailbelow.

A positive hardness gradient having a magnitude of from about 1 to about7 Shore C hardness points generally defines a shallow positive hardnessgradient. A positive hardness gradient having a magnitude of greaterthan about 7 to about 22 Shore C hardness points generally defines a“medium” positive hardness gradient. In turn, positive hardness gradienthaving a magnitude of more than about 22 Shore C hardness pointsgenerally defines a “steep” positive hardness gradient.

A hardness gradient having a magnitude within +1 or −1 Shore C hardnesspoint is generally considered to define a “zero” hardness gradient.

And an outer surface hardness (solid inner core/outer core layer) thatis less than the respective geometric center hardness/inner surfacehardness by more than about 1 Shore C hardness point is generallyconsidered to define a negative hardness gradient.

Thus, the cores and core layers of golf balls of the invention may havevarious hardnesses and hardness gradients as known in the golf ball artdepending on the particular golf ball playing characteristics beingtargeted. For example, cores/core layers may have a geometric centerhardness and a surface harness such that the hardness differencetherebetween is zero or less than 3 Shore C hardness points; or thegeometric center hardness may be less than or greater than the surfacehardness by up to 7 Shore C; or the surface hardness of the core may begreater than the geometric center hardness to define a positive hardnessgradient of about 1 to 12 Shore C hardness points, or of about 12 to 22Shore C hardness points. However, any known hardness gradient profilecan be selected and implemented in golf ball constructions herein. Andat least one cover layer may be formed over/about the core.

In any of these embodiments the core may conceivably be replaced with acore having two or more layers wherein at least one core layer has ahardness gradient.

Compression. As disclosed in Jeff Dalton's Compression by Any OtherName, Science and Golf IV, Proceedings of the World Scientific Congressof Golf (Eric Thain ed., Routledge, 2002) (“J. Dalton”), severaldifferent methods can be used to measure compression, including Atticompression, Riehle compression, load/deflection measurements at avariety of fixed loads and offsets, and effective modulus. For purposesof the present invention, compression refers to Soft Center DeflectionIndex (“SCDI”). The SCDI is a program change for the Dynamic CompressionMachine (“DCM”) that allows determination of the pounds required todeflect a core 10% of its diameter. The DCM is an apparatus that appliesa load to a core or ball and measures the number of inches the core orball is deflected at measured loads. A crude load/deflection curve isgenerated that is fit to the Atti compression scale that results in anumber being generated that represents an Atti compression. The DCM doesthis via a load cell attached to the bottom of a hydraulic cylinder thatis triggered pneumatically at a fixed rate (typically about 1.0 ft/s)towards a stationary core. Attached to the cylinder is an LVDT thatmeasures the distance the cylinder travels during the testing timeframe.A software-based logarithmic algorithm ensures that measurements are nottaken until at least five successive increases in load are detectedduring the initial phase of the test. The SCDI is a slight variation ofthis set up. The hardware is the same, but the software and output haschanged. With the SCDI, the interest is in the pounds of force requiredto deflect a core x amount of inches. That amount of deflection is 10%percent of the core diameter. The DCM is triggered, the cylinderdeflects the core by 10% of its diameter, and the DCM reports back thepounds of force required (as measured from the attached load cell) todeflect the core by that amount. The value displayed is a single numberin units of pounds.Coefficient of Restitution (“CoR”). The CoR is determined according to aknown procedure, wherein a golf ball or golf ball sub-assembly (forexample, a golf ball core) is fired from an air cannon at two givenvelocities and a velocity of 125 ft/s is used for the calculations.Ballistic light screens are located between the air cannon and steelplate at a fixed distance to measure ball velocity. As the ball travelstoward the steel plate, it activates each light screen and the ball'stime period at each light screen is measured. This provides an incomingtransit time period which is inversely proportional to the ball'sincoming velocity. The ball makes impact with the steel plate andrebounds so it passes again through the light screens. As the reboundingball activates each light screen, the ball's time period at each screenis measured. This provides an outgoing transit time period which isinversely proportional to the ball's outgoing velocity. The CoR is thencalculated as the ratio of the ball's outgoing transit time period tothe ball's incoming transit time period(CoR=V_(out)/V_(in)=T_(in)/T_(out)).

Modulus, Tensile Strength and Ultimate Elongation

Modulus, tensile strength and ultimate elongation of golf ball layermaterials may be targeted as known in the art. As used herein, “modulus”or “flexural modulus” refers to flexural modulus as measured using astandard flex bar according to ASTM D790-B; tensile strength refers totensile strength as measured using ASTM D-638; and ultimate elongationrefers to ultimate elongation as measured using ASTM D-638.

A golf ball of the invention may further incorporate indicia, which asused herein, is considered to mean any symbol, letter, group of letters,design, or the like, that can be added to the dimpled surface of a golfball.

Golf balls of the present invention will typically have dimple coverageof 60% or greater, preferably 65% or greater, and more preferably 75% orgreater. It will be appreciated that any known dimple pattern may beused with any number of dimples having any shape or size. For example,the number of dimples may be 252 to 456, or 330 to 392 and may compriseany width, depth, and edge angle. The parting line configuration of saidpattern may be either a straight line or a staggered wave parting line(SWPL), for example.

It is understood that the system and method of the invention asdisclosed, described and illustrated herein represent only some of themany embodiments of the invention. It is appreciated by those skilled inthe art that various changes and additions can be made to such systemand method without departing from the spirit and scope of thisinvention. It is intended that all such embodiments be covered by theappended claims.

Other than in the operating examples, or unless otherwise expresslyspecified, all of the numerical ranges, amounts, values and percentagessuch as those for amounts of materials and others in the specificationmay be read as if prefaced by the word “about” even though the term“about” may not expressly appear with the value, amount or range.Accordingly, unless indicated to the contrary, the numerical parametersset forth in the specification and attached claims are approximationsthat may vary depending upon the desired properties sought to beobtained by the present invention. At the very least, and not as anattempt to limit the application of the doctrine of equivalents to thescope of the claims, each numerical parameter should at least beconstrued in light of the number of reported significant digits and byapplying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the invention are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical value, however, inherently contain certainerrors necessarily resulting from the standard deviation found in theirrespective testing measurements. Furthermore, when numerical ranges ofvarying scope are set forth herein, it is contemplated that anycombination of these values inclusive of the recited values may be used.

Although systems, methods and golf balls have been described herein withreference to particular parts, means and materials, it is to beunderstood that the invention is not limited to the particularsdisclosed and extends to all equivalents within the scope of the claims.

It is understood that the manufacturing methods, compositions,constructions, and products described and illustrated herein representonly some embodiments of the invention. It is appreciated by thoseskilled in the art that various changes and additions can be made to thesystem, method, compositions, constructions, and products withoutdeparting from the spirit and scope of this invention. It is intendedthat all such embodiments be covered by the appended claims.

What is claimed is:
 1. A golf ball comprising a core, a cover and acoating layer disposed entirely about an outer surface of the cover;wherein the coating layer has a first color region having a first colorappearance; a second color region having a second color appearance thatis different than the first color appearance; and a transition colorregion that is transitionally disposed between each of the first colorregion and the second color region and has a transitional colorappearance comprised of the first color appearance and the second colorappearance.
 2. The golf ball of claim 1, wherein the transitional colorregion is disposed circumferentially about the outer surface of thecover.
 3. The golf ball of claim 1, wherein the first color appearanceis at least partially overlaid with the second color appearance withinthe transition color region; and wherein the second color appearance isat least partially overlaid with the first color appearance within thetransition color region.
 4. The golf ball of claim 1, wherein the covercomprises a plurality of dimples, and the coating layer is applied ontothe outer surface of the cover such that more dimples of the pluralityare located within the transition color region of the coating layer thanare located within each of the first color region and the second colorregion of the coating layer.
 5. The golf ball of claim 1, wherein thecover comprises a plurality of dimples, and the coating layer is appliedonto the outer surface of the cover such that more dimples of theplurality are located within each of the first color region and thesecond color region of the coating layer than are located within thetransition color region of the coating layer.
 6. The golf ball of claim1, wherein the cover comprises a plurality of dimples, and the coatinglayer is applied onto the outer surface of the cover such that an equalnumber of dimples of the plurality are located within each of the firstcolor region, the second color region, and the transition color regionof the coating layer.
 7. The golf ball of claim 1, wherein the coatinglayer is applied onto the cover such that at least one dimple ispartially located in the transition color region of the coating layerand partially located in one of the first color region or the secondcolor region.
 8. The golf ball of claim 1, wherein the cover comprises aplurality of dimples, and the coating layer is applied onto the coversuch that greater than one row of dimples and up to seven rows ofdimples are located within the transition color region of the coatinglayer.
 9. The golf ball of claim 1, wherein the cover comprises aplurality of dimples, and the coating layer is applied onto the coversuch that at least four rows of dimples are located within each of thefirst color region and the second color region of the coating layer. 10.The golf ball of claim 1, wherein the cover has at least one transitiondimple that is located within the transition color region and has atransition dimple surface that is coated with the first color appearanceand the second color appearance such that the first color appearance andthe second color appearance are juxtaposed on the transition dimplesurface.
 11. The golf ball of claim 10, wherein the transition dimplehas a first side and a second side; wherein a first pole of the firstcolor region is closer to the first side than the second side; andwherein a second pole of the second color region is closer to the secondside than the first side; and wherein the first color appearance islocated on the second side and the second color appearance is located onthe first side.
 12. The golf ball of claim 1, wherein a first pole ofthe golf ball is included in the first color region; an opposing pole ofthe golf ball is included in the second color region; and an equator ofthe golf ball is disposed between the first pole and the second pole andis at least partially located in the transition color region.
 13. Thegolf ball of claim 1, wherein the cover has a third color appearancethat is opaque, translucent, clear colored, or a combinations thereof;and wherein the first color appearance and/or the second colorappearance is clear-colored, translucent or at least partiallytransparent; such that the transitional color appearance is comprised ofeach of the first color appearance, the second color appearance, and atleast a portion of the third color appearance.
 14. The golf ball ofclaim 1, wherein the transition color region is transitionally disposedabout an equator of the golf ball asymmetrically; and wherein the coverhas a third color appearance that is opaque, translucent, clear colored,or combinations thereof; and wherein the first color appearance or thesecond color appearance is clear-colorless; such that the transitionalcolor appearance is comprised of the first color appearance or thesecond color appearance and at least a portion of the third colorappearance.
 15. The golf ball of claim 1, wherein the cover has a thirdcolor appearance that is opaque, translucent, clear-colored, orcombinations thereof.
 16. A method of making a golf ball comprising thesteps of: providing a subassembly; providing a coating layer about thesubassembly by: applying a first colorant having a first colorappearance onto an outer surface of the subassembly at a first pole ofthe subassembly; and applying a second colorant having a second colorappearance that is different than the first color appearance onto theouter surface of the subassembly at an opposing pole of the subassembly;such that: the first colorant creates a first color region of thecoating layer on the outer surface of the subassembly that includes thefirst pole and has the first color appearance; and the second colorantcreates a second color region of the coating layer on the outer surfaceof the subassembly that includes the opposing pole and has the secondcolor appearance; and the first colorant and the second colorantcollectively create a transition color region that is transitionallydisposed between the first color region and the second color region andhas a transitional color appearance that is comprised of the first colorappearance and the second color appearance.
 17. The method of making agolf ball of claim 16, wherein the transition color region extendscircumferentially about the outer surface of the subassembly.
 18. Themethod of making a golf ball of claim 16, wherein a first colorant spraygun applies the first colorant onto the outer surface of the subassemblyat the first pole and a second colorant spray gun applies the secondcolorant onto the outer surface of the subassembly at the opposing pole;and the transitional color appearance is created and/or adjusted withinthe transition color region by pre-selecting and/or coordinating atleast one of i) relative volumes of first colorant and second colorantuse; ii) an atomization pressure of each of the first colorant spray gunand the second colorant spray gun; ii) a spray gun pressure of each ofthe first colorant spray gun and the second colorant spray gun; and/ororder that each of the first colorant spray gun and the second colorantspray gun spray colorant onto the outer surface of the subassembly. 19.The method of making a golf ball of claim 16, wherein the first colorantand the second colorant are applied onto the outer surface of thesubassembly at opposing poles of the subassembly simultaneously.
 20. Themethod of making a golf ball of claim 16, wherein the first colorant andthe second colorant are applied onto the outer surface of thesubassembly at opposing poles of the subassembly sequentially.
 21. Themethod of making a golf ball of claim 16, wherein the first colorant andthe second colorant coat the outer surface of the subassembly within thetransition color region such that at least one portion of the coatinglayer is comprised of the first colorant being overlaid with the secondcolorant and such that at least one different portion of the coatinglayer is comprised of the second colorant being overlaid with the firstcolorant.
 22. The method of making a golf ball of claim 16, wherein asurface coverage ratio of percent surface coverage of the first colorantwithin the first color region, to percent surface coverage of the secondcolorant within the second color region, is about 1:1; and wherein thetransition color region: i) has a greater surface coverage of the firstcolorant than of the second colorant adjacent the first color region;and ii) has a greater surface coverage of the second colorant than ofthe first colorant adjacent the second color region.
 23. The method ofmaking a golf ball of claim 16, wherein the first colorant and thesecond colorant coat a transition dimple surface of at least onetransition dimple of the subassembly within the transition color regionsuch that the first color appearance and the second color appearance arejuxtaposed on the transition dimple surface.
 24. The method of making agolf ball of claim 16, wherein the outer surface of the subassembly hasa third color appearance that is opaque, translucent, clear colored, orcombinations thereof; and wherein the first color appearance and/or thesecond color appearance is clear-colored, translucent or at leastpartially transparent; such that the transitional color appearance iscomprised of each of the first color appearance, the second colorappearance, and at least a portion of the third color appearance. 25.The method of making a golf ball of claim 16, wherein the transitioncolor region is transitionally disposed about an equator of the golfball asymmetrically; wherein the outer surface of the subassembly has athird color appearance that is opaque, translucent, clear colored, orcombinations thereof; and wherein first color appearance or the secondcolor appearance is clear-colorless; such that the transitional colorappearance is comprised of the first color appearance or the secondcolor appearance and at least a portion of the third color appearance.26. The method of making a golf ball of claim 16, wherein the cover hasa third color appearance that is opaque, translucent, clear-colored, orcombinations thereof.